R6 Yamaha 2003
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R6 Yamaha 2003
Leading the 600 class
"You might as well call 2003 the 'Year of
'Sport Rider,' June 2003
Yamaha introduces the all-new 2003 YZF-R6
a 2nd generation Supersport...
...Introduced September 1998, a second generation R6 was designed to remain true to the original machine’s character, while offering increased engine performance, class leading handling, reduced emissions and new bodywork. Yamaha's first R6 added a whole new dimension to the Supersport market, with a ultra-responsive high-revving engine, agile handling performance, and aggressive R-series styling.
The Development Team for the 2nd generation R6 identified four main aims:
...Increase cornering performance on secondary roads and on the racetrack
...Offer higher levels of exciting engine performance
...Create radical new bodywork that is instantly recognizable as being second generation R6
...Enhance overall quality and reduce exhaust emissions to EU2 standards
...Yamaha has achieved this by producing a virtually all-new engine and by using a new advanced Controlled Filling Die-casting technology patented by Yamaha and thus creating a dynamic new race-bred R6 that offers unrivalled, next-generation Supersport performance.
...The most significant upgrade seen on the new R6 engine is the adoption of a suction-piston type electronic fuel injection system that is similar to the design used on the highly acclaimed 2002 YZF-R1 model.
...On many other conventional motorcycle fuel injection systems the volume of intake air supply is controlled using information from an air pressure sensor, whereas on the new R6, in addition, the air supply is regulated by the motion of a free piston that moves in conjunction with air pressure fluctuations. This regulation of the inlet air volume by suction-pistons gives a much more linear and natural carburetor-like throttle response at smaller throttle openings, while still retaining outstanding efficiency, excellent reliability and reduced emissions associated with electronic fuel injection.
...the new suction-piston type electronic fuel injection system plays a significant role in shaping the exciting character of the new engine, which features a second acceleration curve coming in at 8,000rpm that then runs smoothly through to the maximum power output at 13,000rpm.
...All new, a high-rigidity cast aluminium Deltabox III frame.
...Over the last four years the R6 has set the standards for handling in the middleweight supersport class.
...The second generation R6 runs with a totally new Deltabox III aluminum frame that offers extremely high rigidity combined with low weight, making it one of the most advanced and sophisticated designs ever seen on a supersport motorcycle.
...What makes this new Deltabox III frame so special is the fact that it is a completely cast aluminum design the first time this technology has been used on a production motorcycle.
...The new chassis runs with the same short 1,380mm wheelbase and 24 1/4 degree caster angle as the original model, but important changes have been made to the front fork geometry. The upper triple clamp is all-new for 2003, and runs with a reduced 35mm offset, compared with 40mm on last year’s model.
...This revised geometry results in lighter and more responsive steering performance. Together with the use of lighter fork tubes on the 43mm forks, and a new front wheel axle secured by a total of four pinch bolts, these changes enhance steering feedback and give the front end of the new R6 a more responsive feel.
...Newly designed 5-spoke alloy wheels reduce unsprung weight, and this improves suspension action and responsiveness for improved handling in all conditions. The 5-spoke design uses special rims that have been die-cast using a 4-directional method rather than the conventional 2-directonal system, and this has allowed the designers to reduce weight further.
...Tire sizes remain the same as previously, with a 120/60 ZR17 front radial and 180/55 ZR17 rear radial offering high levels of traction.
...As well as improving front and rear suspension performance, these lighter wheels also have a reduced gyroscopic effect, and this makes for quicker directional changes and allows the machine to be banked more easily into a turn.
'Sport Rider,' April 2003, R6 edited review
"The previous generation R6 middleweight ripper was the baseline for many sportbike qualities.
It is time for a recalibration."
...The old R6 had benchmark
steering, quickness, 15.5k redline, a well-behaved chassis---it had it all.
The R6 was the bike of the year in 1999 when it was introduced. Win or
lose, every comparison test including the baby R was full of praise for it.
...The new R6's facelift incorporates many of the tweaks made in the 2002 R1----fuel injection, subtle geometry changes, with detail changes throughout aimed at refining an already good package.
...In addition the little R benefits from interesting new technology that makes the 02 R1 changes seem small in comparison. Such as controlled filling die casting with makes the frame, subframe, swingarm and wheels thinner, lighter, stronger, helping to make the 03 R6 eight pounds lighter.
...Ninety percent of the engine parts are new and along with fuel injection for the first time produce an additional three horsepower, with emphasis on improving bottom-end power and overrev.
...The design goals were the same as the R1's, increasing agility and stability, enhancing feel at full-lean, improving throttle response, and extending power higher in the rev range. The objective being to change the R6's focus from a very extreme layout to an extremely efficient layout and obtain "Yamaha philosophy of perfect man/machine interaction." "Dancing with power" was the theme.
...In the street test ride the bike handled everything that was thrown at it with ease. The biggest improvement is the added power in the middle third of the range, from 5-8k rpm's, where the 03 R6 picks up cleanly and pulls strong. The gearbox now shifts much smoother than previously with first to second noticeably easier, however still not on the par with the other 600's in the class.
...Fuel injection is a marked step better than the carbs used previously but not the jump expected based on the R1's similar system. Throttle response was crisp, but some of the carbureted R6's off/on throttle abruptness remains and a steady hand is needed to get the power on smoothly at lower rpm's. But in any other rpm situation, the fuel injection performance is top notch.
...After a long day the 5mm closer reach to the bars and reshaped tank did not produce the cramped hand feeling on the older models with a more drooped clip-on. The ergonomics seemed to fit better for long days on the street.
...Another nice change is the engine vibration reduction at the 6k rpm mark. The new balancing spec of the crankshaft has a positive effect on vibration response.
...The new R6 is stiffer---both in the chassis and the suspension. The overall feel is the R6 is more taut---one feels the bumps a little more but the chassis pitches less going over bumps. Flicking the new R6 through S-turns is easier than even the older R6.
...The R6 and R1 share an identical instrument panel, including a programmable shift light.
...Triple clamps have less offset and give 5mm additional trail, with the steering head moved forward to compensate. The seat is 5mm further forward and the tank has been reshaped being thinner at the seat/tank junction.
...The ram air inlet is the same size as the 02 model, but reshaped. The buffers in the intake runners are slightly smaller. The airbox increased from 7.3L to 7.6L.
...The new curved radiator increases airflow by 30%. The ring-type fan (all blades joined at the outer edge) is located at the point coolant enters the radiator rather than in the center of the radiator. This means the fan is more efficient plus not blocking air flow to the radiator, all increasing cooling significantly.
...A new shock mounts to the frame using a clevis pin that allows the use of shims for ride height adjustment. Rear wheel travel had been reduced 10mm. The spring rate is slightly increased. The shock's linkage plates are aluminum instead of steel.
...The front brakes remained essentially the same with the exception of pad compound and a number of mounting points and buttons.
...The inner fork tube thickness as been reduced from 2mm to 1.5 mm. Fork travel has been reduced slightly and spring rate increased by approximately 10%.
...The two-piston rear brake caliper has been replaced with a smaller single-piston unit.
...The main frame, subframe, swingarm and wheels are all made with the controlled filling die case process. The swingarm pivot is 10mm closer to the countershaft sprocket so the swingarm can be 10mm longer for increased rear wheel traction, and yet leaving the wheelbase the same.
...The entire OEM header system is stainless steel with the inside of the muffler titanium. The entire exhaust system is 2.2lb lighter, even with a catalyzer in the canister so all U.S. bikes meet CA emissions regulations.
...New piston design has a slightly thicker skirt on the intake side, tapered-bore pins, and a thicker top to reduce oil consumption.
...Piston/cylinder friction has been reduced through the use of a liner-less cylinder, in which the ceramic composite plating is applied directly to the bores rather than to an additional aluminum liner. This makes for a more consistent gas seal and reduces oil consumption.
...The shape of the crankshaft has been changed to improve the balance factor of the engine, plus it weights slightly less.
...Single-piece cam caps have been replaced with two smaller caps to reduce weight. The intake cams have 0.4mm more life. The valve springs have 10% more preload but with similar pressure once the valve is open. The small holes next to the spark plug tunnels are the air induction ports, which are not integrated into the cylinder head.
...The 37mm carbs of the old R6 are replaced with 38 mm throttle bodies, which are similar to the R1 units and use a CV-type secondary slide to smooth out throttle response.
...Gear ratios are unchanged but the number of dogs for second and fifth gear have been increased from 3 to 5 to increase the number of opportunities for the gears to engage during each revolution thus easing shifting. The shift cam is heavier and the roller diameter is larger, to make the shift drum turn quicker and more positively.
'Sport Rider,' June 2003, 600 test notes
...The Yamaha R6 weighs 415
lb topped off with fuel as opposed the Honda 600RR at 445 lb.
...The Yamaha R6 dominated at the track.
...The R6's substantial revisions and upgrades to an already great package ensured that the previous model's strong points were not diluted. The 03 R6 retains the supreme agility of the old model, but added trail in the steering geometry ahs tamed its previously nervous traits. Add a motor with significantly beef-up midrange and top-end, and slice over 11 lb off its already lithe build, and you have got the recipe for a middleweight ripper.
...The R6 has one of the most well-sorted suspension packages yet experienced. The ride is supple enough to smooth over the small irregularities, yet firm enough to handle the big hits without losing its composure. Superb front-end feedback lets the rider exploit the chassis' angle handling to the fullest, and since the already fantastic Yamaha brakes have less weight to deal with, corner entry and mid-corner speeds increase dramatically.
...The R6 basically enables the rider to put it anywhere on the track or road, opening up more line choices in any turn.
...Never mind the R6 turned the quickest test lap times, it was the unanimous choice of the testers as the bike they felt most comfortable on, from novice to expert.
..."The R6 exploits its performance advantage armed with a chassis that is nearly as rock-stable as the Honda, while boasting slightly better suspension and much more agility, the R6 simply shreds curvy pavement with far less effort---both physically and mentally. The Honda feels nearly as small as the diminutive Yamaha, but the R6 matches that tiny perception with a razor-sharp handling character (that does not feel like it will cut you if you are not careful, like it did last year) and a lightweight, yet balanced feel. The same agile handling that opens up more line choices on the track becomes even more of an asset on the street, where the amount of usable pavement shrinks dramatically. The fact that the Yamaha's motor is more responsive with better power all-round than last year is just icing on the cake. You just feel like you can do no wrong on the R6."
..."The greatest part is that the R6---as well as the rest of the 600 class---proves that just because manufacturers are looking to design a racebike first, sportbike second, it does not result in a motorcycle that is completely incompatible for street use. We all win."
Specs for the Yamaha YZF-R6:
...$7999 list (7500 +/- buy).
...Liquid cooled, forward inline, 4-stroke parallel cylinder
...DOHC 16 valves, 600cc..
...12.4 to 1 compression ratio.
...Constant mesh six speed transmission with chain.
...Gear ratio: 1st 2.846, 2nd 1.947, 3rd 1.556, 4th 1.333, 5th 1.190, 6th 1.083.
...Primary reduction ratio 1.955
...Secondary reduction ratio 3.000
...Bore 65.5mm; Stroke 44.5 mm.
...Suction piston type electronic fuel injection; 38mm throttle bodies.
...Frame diamond shaped cast aluminum Deltabox III
...Telescopic fork 43 mm conventional cartridge with 4.7 inches of travel.
...Single rear shock with 4.7 inches of travel.
...Rake of forks 24.0 degrees; Trail 3.4in or 86mm.
...Wheelbase 54.3 in. or 1380 mm.
...Weight dry 388 lb or 176 kg; Weight topped with fuel 415 lb. or 188 kg.
...Seat height, 32.3 inches.
...Fuel consumption 34 to 40 mpg; average of 38 mpg.
...Fuel capacity, 4.5 US gal.
...Front brake dual discs, 298 mm.
...Rear brake single disc, 220mm.
...OEM front tire 120/60ZR-17 Dunlop D208F L Sportmax Radial.
...OEM rear tire 180/55ZR-17 Dunlop D208R L Sportmax Radial.
...Supremely agile, non-nervous handling.
...Lightest 600 ever.
...Torque curve a little lumpy.
...Larger riders might be cramped.
...Hard to find negatives.
Suggested Suspension Settings
...Spring preload: 6 lines showing.
...Rebound dampening: 2 clicks out from full stiff.
...Compression dampening: 6 clicks out from full stiff.
Fork Tubes: |
...0mm showing with stock Dunlop 208ZR tires.
...10mm showing above flat portion of clip-on with Pirelli Supercorsa Tires.
...Spring preload position 4 from full soft.
...Rebound dampening: 11 clicks out from full stiff.
...Compression dampening: 9 clicks out from full stiff.
Performance (Yamaha values)
Top Speed 161.6 mph
0 - 30 mph 1.6 seconds
0 - 60 mph 3.28 seconds
0 - 100 mph 6.8 seconds
0 - ¼ mile 11.25 @ 130 mph
EPA City / Hwy 38/44 mpg
2003 600 Performance Values
|03 600 Model||
|Yamaha R6||105.5@12,750rpm||44.7@11,750rpm||158.0 firstname.lastname@example.org||4.46 sec||5.22 sec|
|Honda CBR600RR||107.2@ 13,500rpm||45.4@11,000rpm||162.2 mph||10.73sec@ 129.7mph||4.23 sec||4.28 sec|
|Kawasaki ZX-6R||107.5@13,000rpm||46.4@11,000rpm||158.5 mph||10.67sec@ 131.0mph||4.34 sec||4.30 sec|
|Suzuki GSX-R600||103.4@13,250rpm||46.5@10,750rpm||158.8 email@example.com||5.36 sec||6.51 sec|
|2003 600's Specs|
|Model||Retail||cc's||Dry Wt.||Wet Wt.||Compression||Bore x Stroke||Injection||Throttle||Fuel Range||Average|
|Yamaha||$7999||600||388lb||415lb||12.4 to 1||65.5x44.5mm||Electronic||38mm||34-40 mpg||38 mpg|
|Honda||$8599||599||416lb||445lb||12.0 to 1||67.0x42.5mm||DSFI||40mm||30-38 mpg||34 mpg|
|Kawasaki||$7999||636||389lb||418lb||12.8 to 1||68.0x43.8mm||Digital||38mm||34-40 mpg||37 mpg|
|Suzuki||$7999||599||394lb||423lb||12.2 to 1||67.042.5mm||Electronic||38mm||34-39 mpg||37 mpg|
...All engines are liquid-cooled,
inline, 4-stroke, four cylinders.
|2003 600's Chassis Specs|
|Model||Forks & travel||Rear travel||Rake||Trail||Wheel Base|
|Yamaha||43mm, 4.7in||4.7in||24.0 deg.||3.4 in.||54.3 in.|
|Honda||45mm, 4.7in||4.7in||24.0 deg.||3.7 in.||54.7 in.|
|Kawasaki||41mm, 4.7in||5.3in||24.5 deg.||3.7 in.||55.1 in.|
|Suzuki||45mm, 4.9in||5.1in||24.0 deg.||3.8 in.||55.1 in.|
...All forks are conventional except
for the inverted on the Kawasaki.
...All 600's use a single rear shock.
2003 600's OEM Tires
|Model||Front Tire||Rear Tire|
|Yamaha||120/60ZR-17 Dunlop D208F L Sportmax radial||180/55ZR-17 Dunlop D208L Sportmax radial|
|Honda||120/70ZR-17 Dunlop D208F K Sportmax radial||180/55XR-17 Dunlop D208K Sportmax radial|
|Kawasaki||120/65ZR-17 Bridgestone BTO19F Battlax radial||180/55ZR-17 Bridgestone BTO12R G Battlax radial|
|Suzuki||120/70ZR-17 Dunlop D207F U Sportmax||180/55ZR-17 Dunlop D207U Sportmax|
'Sportrider' edited rider
..."While we were 'tweaking' the others, the Yamaha did not need any attention. It is not that the new o3 R6 is outstanding in any one particular category, but it simply does everything well and nothing wrong. On the track, you are the limit---it is the best tool for going to a track day to learn something. and on the street, it is so forgiving that it is not a question of how fast you can go, but how fast you really want to go." AT
..."It is going to take some motorcycle to topple the 03 YZF-R6. Throughout the flog, I kept tamping down my favorable first impressions, trying to find reasons to criticize the R6. I could not...and still cannot. The R6 is quick, friendly, well-suspended (although a touch soft for some), smooth, cheerful and supremely easy to ride. It is also comfortable and surprisingly practical. For the street and track...send me an R6." MC
..."The Yamaha R6 has the other bikes beat. When I first hopped on it, I felt at home. Great ergonomics, along with a strong powerplant stopped by decent brakes put the Yamaha over the top. The biggest difference was the handling. I fell right into rhythm putting the bike right where I wanted to, and the suspension was not too far off my liking. the R6 really made me feel that I could do not wrong." CN
..."As for the two big hitters in this year's 600 shootout it is really a one-sided affair with the R-6 coming away as the benchmark for 2003. The Honda does not have the razor-sharp feel or refined design and style of the R6 and thus ends up second on the box. The r6 simply put, gets you corner to corner quicker and easier than any of its rivals...not to mention the fact that it looks great while doing so." SM
..."I must admit that deep inside I was expecting the Kaw or Honda to come out on the top. The new R6 simply shows what a lightweight, well-set-up chassis and suspension will do for a sportbike. It may not have the strongest motor, yet the R6's fantastic balance of light weight, spot-on-suspension rates, and agile-but-stable steering manners let it make the most of what it has. And to it with far less effort at all the controls than the others." KK
R6 notes from Yamaha
Yamaha's intro of the R6
...Yamaha's SuperSport Philosophy is to develop and market innovative 'state of the art' motorcycles which lead the SuperSport class in terms of performance, handling and styling.
...The R-series models have a strong individual philosophy and identity.
...The R1 was introduced in 1997, followed by the R6 and R7 in 1998. The first R6 was the most radical supersport with extremely sharp handling, an ultra high revving engine and an ultra compact chassis.
...The R6 for 2003 is completely new, fully re-engineered with highly advanced state of the are technology, moving from the past very extreme layout to an extremely efficient layout. The new R6 follows Yamaha's philosophy of 'perfect man/machine interaction.'
...'Dancing with power' was the new R6's development theme. The ultimate experience of leading the machine according to the riders rythum.
...The objectives of 'dancing with power' were to increase sharpness and stability, enhance handling at deep banking angles, increase agility, achieve instant and sensitive throttle response, improve acceleration in the over rev area.
...The results are a responsive high performing engine with increased performance and precise engine control. The new air intake system is optimized for efficiency in terms of air buffer capacity, air flow and with a 0.3L larger air cleaner box.
...The camshaft has been reshaped for improved balance and valve lift was increased from 7.8mm to 8.2mm, giving increased engine performacne and improved acceleration feeling.
...New on the R3 in 2003 is a unique electronic fuel injection system with 38mm throttle bodies. The new Nippon injectors have improved low and high rpm flow, thus smooth throttle response at any rpm level. The R6 produces 123hp at the crank with max air intake, for improved, excellent response from mid range rpm's upwards.
...The gearbox has a re-engineered shift cam. The stopper roller diameter was increased from 14mm to 16mm, for smoother and quicker shifting.
...The new frame is more compact, light weight and rigid, for increased agility and higher stability. The center of mass concentration is even more around the rolling axis near the engine compartment with weight reduction occurring both at the front and rear of the R6.
...The completely new Delta Box III frame is not made by CF aluminum die casting with only 2 welds needed as opposed to the 16 weld on previous models, thus there is a 50% increase in torsional or twisting rigidity. The swing arm is also CF die casted, being longer and more rigid.
...The new exhaust system is stainless steel with an aluminum muffler with titanium inner pipes to create a total weight reduction of 2.2 lb.
...The newly designed 5 spoke wheels reduce spinning weight by %4 and thus improve balance.
...The chassis geometry was enhanced with the front fork offset being reduced from 40mm to 35mm and the trail increased from 81 to 86mm, which gives increased cornering stability.
...The center distance from the pivot of the rear axle to the swing arm pivot was increased by 10mm as the drive sprocket is located 10mm closer to the swing arm pivot. This increases traction during acceleration by increasing rear leverage on the back wheel.
...New 43 mm Kayaba front forks have reduced wheel travel from 130mm to 120mm for reduced pitching.
...Utilizing cutting edge technology for ultimate engine development coupled with a new level of frame layout has produced the industry leading 2003 R6 with the fully integrated design approach. Stable and sharp to attack the corners, neutral steering at deep banking angles, quick and light for swift direction changes, instant throttle response at mid range rpm, increased performance for unmatched acceleration. Yamaha's way of 'dancing with power' with an R6. Appropriate for riders insisting upon nothing less than track star performance right out of the box
03 R6 Frame
...Called the Deltabox III frame.
...First production frame from a mold casting process where the aluminum is forced into a frame mold under pressure.
...Only two weld points (16 on previous frame), thus weight is reduced and frame has increased rigidity.
...Increase in frame precision allows a direct point mounting system (rather than three point forward adjustable system), thus better handling and rider feel.
...CF or controlled filling of the frame molds produces stronger and lighter parts as the material thickness can be engineered and controlled. Molded parts contain five times less oxide content than traditional die-cast parts thus the welds are a higher quality producing very high rigidity.
03 R6 Rear Frame
The R6 rear frame and rear arm utilizes the "Controlled Filling Aluminum Die Casting Technology" for the first time ever on a production model.
...The 03 R6 has better
traction created by more rigidity and a longer rear arm.
...Because of the CF casting the rear arm shows a smooth curved design and minimal thickness of 2.5mm at its less stress points.
...The rear frame is 2mm at some points, thus there is weight reduction plus an ideal blend between frame rigidity and stress absorption.
...The longer rear arm offers better positioning of the the offset from 96mm to 86mm on the 03 R6, between the drive axis and the pivot point. The chain tension effect is therefore reduced during hard acceleration.
...The rear arm increased in length by 10mm, to 575.5mm.
03 R6 Fork
The R6 is more stable and feels lighter in the steering.
...The inner fork tube is thinner.
...Wheelbase and caster remained the same, but the fork offset increased 5mm to 35 mm.
...There has been a change in the front axle bolt system.
...This adds up to a more stable, lighter steering geometry.
03 R6 Wheels
Improved strength to rigidity balance assists the suspension sensitivity.
...A lighter five
spoke wheel reduces spinning weight and increases suspension sensitivey.
...The new thinned out design gives an optimum strength and rigidity balance.
03 R6 Front
Assembly and Headlights
...The 'gatling beam' headlights are suppose to have better performance.
...The front end has been reshaped for better/superior protection.
03 R6 Fuel
This is the first year for the R6 to be fuel injected.
...Yamaha uses the
'suction piston' type of fuel injection. The motion of a free piston
moving in relationship to the air pressure fluctuations regulates air intake
flow. In standard injections system the air volume supply is controlled by
an airflow sensor.
...The results are a natural carburetor type of linear (even) throttle feeling, but with the outstanding response and reliability of modern electronic control.
...The R6 injection allows for a second acceleration curve beginning at 8k rpm, with excellent top end power output which easily continues past 12.5k rpm until red line at 15.5k rpm.
monitor running conditions, with a microcomputer processing the data and feeding
information into the fuel injection controller.
...Cylinder discrimination sensor.
...Crank rpm sensor.
...Intake air pressure sensor.
...Atmospheric air pressure sensor.
...Intake air temperature sensor.
...Coolant temperature sensor.
...Throttle position sensor.
03 R6 Air Intake
...The air cleaner capacity was increased from 7.3 to 7.6 liters and throttle body was increased from 37 mm to 38 mm, which improves engine response.
...The previous R6's 'ram air system' was retrained, where intake efficiency is increased by utilizing air pressure on the front fairing to increase pressure inside the air box. The frontal air passage opening is lower between the head lights.
...The shape of the air intake passage was changed for optimum fuel injection function.
03 R6 Stock
...The exhaust system was redesigned to improve engine performance and reduce weight.
...Titanium, which is highly resistant to heat, was used for the internal single unit structure, rather than the older two section diffuser.
...The outer cover of the 'can' is aluminum. Even with the catalyzer element the exhaust if 2+ lb lighter than previous models.
...The can is a double layer tube with glass wool packing between the two layers in a curved shape which reduced noise while allowing smooth exhaust gas flow.
...Muffler discoloration should be minimal.
New Engine Parts
...While maintaining the engine character with the same , bore-stroke dimensions, the compression ratio and the combustion chamber shape are altered to boost performance gained from an intake/exhaust efficiency. A power increase of about 3 hp has been achieved without increasing maximum engine rpm Power output: 123 HP/13,000 rpm with ram-air effect (Yamaha test data).
...Liner-less direct plated cylinder and new crankcase design. A new cylinder layout reduces the resistance of the piston in motion. Unlike conventional plated cylinders where a cylinder sleeve is first cast into the cylinder wall and then plated, this new cylinder has no sleeve and applies the plating directly to the inner wall of a die-cast cylinder. A better heat dissipation, optimized strength and a more accurate cylinder shape are the advantages.
...A new crankcase design with enlarged passages between the cylinders reduces fluctuation in air volume caused by the pumping action of the pistons. Together with a new crank balance, this minimizes pumping-related horsepower loss and improves engine response.
03 R6 Honeycomb Catalyzer
...A honeycomb catalyzer mounted inside the muffler acts in combination with an Air Induction (secondary air induction) system, re-burning (oxidizing) the unburned fuel remaining in the exhaust by fresh air supply into the exhaust pipe. The remaining exhaust gas is then further cleaned in the catalyzer. This system enables the YZF-R6 to exceed EU2 emissions standards, without any sacrifice in performance.
...Forged aluminum parts are adopted for the footrest and rear shock absorber. (previously cast aluminum parts). Changes have also been made to the rear brake system (caliper, disc master cylinder changed).
03 R6 The New Radiator
...To accommodate the increased engine performance, the cooling system has been renewed with a round type radiator. A "ring fan" adds a ring around the outside of the fan to achieve more effective air flow for an improvement of 10 to 40% in cooling performance, compared to the existing model.
Redesigned 2003 Yamaha YZF-R6 Hits Harder and Handles Better
Three More Horsepower, Eight Pounds Lighter, And Fuel Injection Make The R6 a Top Contender For the 600cc Class Crown
...In 1999 Yamaha brought forth the original R6, a bike containing the world's first 200-horsepower-per-liter production engine packed in a cutting-edge chassis that rewrote the handling handbook. Light, excruciatingly agile, and revvable beyond 15,000 rpm, the R6 would go on to victory in nearly every 600cc media arena it entered--as well as being named 2001 Bike of the Year by Sport Rider magazine. For 2003, the R6 has undergone a wheels-up redesign, with a stronger, cleaner, fuel-injected engine, a revolutionary frame that's the first ever to use Yamaha's exclusive new casting technology--and a stunningly modern look from the point of its exclusive Gatling-beam headlights to the tip of its LED taillight.
Is Better: Deltabox III
...Fantastic handling has always been job one for the R6 crew, and racing teaches that handling begins with frame rigidity. Thanks to a new, more efficient vacuum-assisted aluminum casting technique which produces a purer, stronger piece, the R6's all new Deltabox III has 50 percent greater lateral frame rigidity than before--and approaches that of the R7 Superbike frame. "Controlled filling aluminum die casting" technology (CF) allows the new frame to be made entirely of aluminum castings--a mass-production first--and from far fewer frame components than before. Where the previous frame required 16 welds, the new bike needs only two. Greater casting precision also allows more rigid engine mounting; in place of adjustable forward engine mounts, the new frame uses direct mounts, which further increase chassis stiffness and enhance feedback.
...CF die casting is used again in the new swingarm, making possible a lighter arm that's also stiffer. CF simply allows placement of more material where it's needed, less where it isn't. Sections of the swingarm are as thin as 2.5 millimeters. For greater traction and feel, the new arm is 10mm longer than before, and the offset between the countershaft axis and swingarm pivot axis has been reduced from 96 to 86mm. While wheelbase remains a quick-turning 1380mm, fork offset has been reduced 5mm, to 35mm, for lighter-feeling, more communicative steering. Functional and stylistic design aspects were considered in unison. That means the new frame looks as radical, and beautiful, as it feels.
Jets, Hello Fuel Injection
...Adaptation of the same critically acclaimed "suction-piston" type fuel injection introduced last season on the R1 gives the new R6 the same feeling of excellent, smooth carburetion--along with the reliability and response of electronic control. Throttle bodies of 38mm diameter replace the 37mm carburetors, and are fed pressurized air through a larger airbox and intake optimized to work with the new injection system.
...Rather than go the traditional route--more peak power via bigger bores and shorter stroke--Yamaha engineers wanted more power but not at the expense of the excellent midrange response and lively feel of its "long-stroke" engine. Instead, they concentrated on improved intake efficiency and reduced pumping and friction losses to extract three more horsepower- 123(with ram-air)--at the same 13,000 rpm as before, with a second power curve beginning at 8000 rpm. Higher-lift cams, with less overlap (made possible by fuel injection) further enhance the R6's strong midrange throttle response. Though engine dimensions, compression ratio and combustion chamber shape are unchanged, 90 percent of the engine parts are new.
...Again, breakthroughs in die-casting now allow production of an upper crankcase/ cylinder block with greatly reduced oxides in the molecular matrix. This produces a much stronger, more consistent cylinder, to which ceramic composite plating can be directly applied, instead of to a cast-in sleeve as before. Benefits include better heat dissipation and a more exact cylinder shape. Combined with stronger, forged pistons and redesigned rings, the new engine enjoys better gas seal and greater piston stability. Other engine changes include reshaped transmission gears and journals for improved shifting, an aluminum oil cooler, increased engine cooling capacity, and rare-earth magnets for a lighter flywheel.
...Once fuel is burned, a catalyzer and air induction system in the exhaust let the new R6 pass the stringent EU2 emissions standard by converting CO to CO2, hydrocarbons to CO2 and H2O, and Nox to N2, H2O and CO2. At the same time, the new exhaust system is 2.2 pounds lighter, quieter and more efficient, thanks to titanium internals with greater volume and higher flow.
Ready To Pounce...
...Technology "Gatling beam" headlight led to the R6's look as well. "This is a case of new technology leading to new design elements... this headlight became the defining element in the front face design. Also, in order to visually express the increased sense of road holding in the front end, we created a side view that gives the impression of the body grasping the front tire...." CF casting let the design team have a larger say in the appearance of the frame and beautiful swingarm. Even the new five-spoke wheels benefit from new casting techniques which make them lighter, stronger and more aesthetically pleasing.
2003 Yamaha YZF-R6 edited
Putting a sharper edge on the 600-class cornering king
...Yamaha has a new YZF-R6 for 2003.
It rolls into the most serious 600 class in years some eight pounds lighter and
packing three additional horsepower. A radically refined aluminum chassis aims
to top any 600-class cornering comparison.
...Starting out with a class-leading package makes radical change unnecessary. The story starts with a revamped ram-air inlet, feeding what Yamaha says is a more efficient pressurized airbox. Four YZF-R1-type 38mm throttle bodies provide the electronic fuel injection. z
...Waging war against friction and pumping losses--power-sapping crankcase pressure fluctuations created by pistons flying around at 15,000 rpm--90 percent of the part numbers in the '03 R6 engine are new. Cams dial in higher lift, and valve springs are stiffened to match
...The compact headlight array uses three "gatling-style" elements. The low-beam pair on the right gets help from a left-side element when you switch to high beam; the inboard element on the left is for looks only.
...Yamaha engineers retained the existing 65.5mm x 44.5mm cylinder dimensions, but the pistons get a 10 percent thicker top ring for less flutter and better sealing against hot, high-velocity combustibles. Crankshaft balance has been carefully recalculated. All that adds up to 117 claimed crankshaft horsepower at 13,000 rpm on Yamaha's dyno--123 hp with street speeds forcing fast-moving atmosphere into the new airbox. Because more power means more heat, there's also a larger curved radiator, allowing 30 percent more airflow to keep everything cool.
...The R1-style instrument pod incorporates a programmable shift light this year. Redline remains at 15,500 rpm.
...The Deltabox III frame shows lessons learned from the '02 R1, along with some tricky manufacturing technique. Employing Yamaha's proprietary Controlled Filling (CF) aluminum die-casting procedure, the '03 R6 frame parts are allegedly 50 percent stiffer--on par with the R7 superbike chassis in terms of rigidity--and radically simpler to build, assembled with two welds rather than the 16 necessary to bond an '02 R6 frame. First used in manufacturing Yamaha's RX-1 snowmobile, CF casting technology lets engineers optimize the flow of molten aluminum into a die, maintaining precise control over the temperature of the die itself and drastically increasing the vacuum inside. With fewer air bubbles sneaking into the mix, aluminum bits can be thinner, lighter and just as strong. The computer-controlled CF process also allows engineers to cast larger, more complex shapes--a big deal when an '02 R1 is comprised of approximately 40 percent aluminum. Yamaha's CF die-casting lets engineers form larger, more complex shapes than ever before. The 2003 frame is assembled with two welds vs. 16 in '02. The new sub-frame is simpler, also.
...The Deltabox III frame shows lessons learned from the '02 R1, along with some tricky manufacturing technique. Thanks to Yamaha's proprietary Controlled Filling (CF) aluminum die-casting procedure, the '03 R6 skeleton is allegedly 50 percent stiffer--on par with the R7 superbike chassis in terms of rigidity--and radically simpler to build, assembled with two welds rather than the 16 necessary to bond an '02 R6 frame. First used in manufacturing Yamaha's RX-1 snowmobile, CF casting technology lets engineers optimize the flow of molten aluminum into a die, maintaining precise control over the temperature of the die itself and drastically increasing the vacuum inside. With fewer air bubbles sneaking into the mix, aluminum bits can be thinner, lighter and just as strong. The computer-controlled CF process also allows engineers to cast larger, more complex shapes--quite a big deal when an '02 R1 is comprised of approximately 40 percent aluminum.
...Wheelbase remained the same at 54.4 inches--another optimal number to R6 designers--but other chassis numbers were tweaked. The swingarm is 10mm longer, and the countershaft sprocket centerline migrates 10mm closer to its pivot point; 10 mm closer to the gearbox output shaft. At 24 degrees, rake is unchanged from '02, but moving the triple clamp closer to the rider stretches trail to 86mm--5mm more than last year--the longer swingarm coupled with the already optimal wheelbase improves steering capabilites. The CF process also serves up a lighter, simpler aluminum sub-frame.
...A new hefty little catalytic converter could have canceled some of that weight loss, but replacing steel muffler entrails with titanium created an exhaust canister that's 2.2 pounds lighter than last year.
...Created via a separate casting process, new five-spoke aluminum wheels are stronger, and will arrive with '02-spec radial rubber: a 120/60ZR-17 front followed by a 180/55ZR-17 rear.
From an R6 rider: The R6 is without any doubt the most fantastic motorcycle that money can buy. It combines speed and style is such a perfectly formed package that it really is very hard to fault. The R6 looks similar to the R1, but they are actually quite different bikes. The R6 was designed as a pure sportsbike for the 600cc class and all the road bits and pieces were added after. The R1 is a road bike which was designed to be as quick and sporty as possible (the closest thing that Yamaha race is the R7). Through the twisties the R6's size and weight are easier to control which can actually makes it a quicker bike although bikes like the R1 may catch up in a straight line. The 'little' R6 is a street riders dream of an affordable, cutting edge supersport that gives no quarters for all round every day riding or a day at the track.
2003 Yamaha YZF-R6
Edited notes from Motorcycle USA; an outstanding review and explanation.
...The 2003 Yamaha R6 turned me into a shift-light junky, a 16,000-rpm user, a second-gear power-wheelie addict. The best part it is available over the counter:) All new for 2003, the R6 has arrived on the scene to some very fierce competition
...Yamaha shaved weight from the old bike by using a new casting process that forces aluminum under high pressure into the mold. This Controlled-Fill casting process results in less porosity in the metal, making it stronger and lighter. Yamaha claims the R6's sleek new frame has the torsional rigidity of its YZR-R7 Superbike while being more than a pound lighter. Only two welds are needed to join the frame as opposed to the previous model's 16. Attached to this is the slickest looking swing arm ever to grace a stock motorcycle. Like the frame, it is produced by the new casting process. Longer by 10mm, it is just 2.5mm at its thinnest point.
...The new five-spoke wheels have been lightened and strengthened. The rear OEM tire is a180/55-17 Dunlop D208 Sportmax. The rear brake has a 220mm disc that gets worked by a two-piston caliper. There is a fair bit of lever travel before lock up.
...The same design that treats the spokes and the hub as one structural unit is used on the front wheel, and it rolls on a 120/60-17 D208. Twin 298mm discs, grabbed by one-piece calipers, handle braking duties. Front brakes are actuated by a five-way adjustable lever and have a nice feel for trail braking or parking lot control. Once the 4-piston calipers begin biting, hang on. The incredible rate in which they haul the diminutive Yamaha to a halt can border on painful.
...There are no earth shattering changes with the conventional 43mm cartridge fork, although the inner tube is now thinner. Adjustable for preload, compression and rebound damping, the stock settings are a good combination for canyon carving and freeway droning. What has been changed is the offset of the triple clamp by 5mm. Wheelbase remains the same though, because the steering head has been positioned 5mm further forward to help give the new Yamaha R6 a greater sense of stability. The front end now feels totally planted in any situation and does not exhibit any nervous feeling mid-corner. Getting on the gas hard or flicking the bike side-to-side in the tight twisties is no cause for complaint either. Previous R6's could be a little skittery under hard acceleration,
...There are no major changes to the fully-adjustable rear shock. Stock settings work fine. The rear shock handles manic acceleration out of the turns with ease. If you can induce any wobbles and weaves on public roads, you probably need to join the overachievers club or get your racing license.
...Yamaha says the R6 gained three horsepower over last year’s model, mostly due to the addition of R-style fuel injection. The suction-piston-style injection uses seven sensors to monitor its progress. Once the fuel is in the cylinders, it is ignited by iridium spark plugs fired by new direct ignition coils. The air box has been enlarged from 7.3 to 7.6 liters and, when pressurized by high-speed incoming air, Yamaha claims a power peak of 123 horsepower at 13,000 rpm.
...Inside the engine, bore and stroke remain the same, with an increase in compression ratio and some combustion chamber reshaping to increase intake and exhaust efficiency. The intake cam now gets a little more lift and is a contributor to the increased horsepower, especially in the midrange. The cylinder is die-cast with no sleeve for reduced piston friction, better heat dissipation and a more accurate shape. The crankshaft has enlarged passages between the cylinders to reduce the fluctuation in air volume caused by the pumping action of the pistons. To further save weight and increase strength, the cylinder and crankcase assembly are a one-piece design.
...All of this high-revving, horsepower-generating action builds up a lot of heat. As such, Yamaha has added a larger, curved radiator and what they call a “ring fan.” The ring seals the fan to the contours of the radiator for a claimed 10-40% improvement in cooling. The cooling fan is located to the side of the radiator so more cooling fins are hit by the oncoming air.
...Exhaust gases are dealt with by a quiet four-into-one exhaust system that, like just about everything else on the new R6, has been redesigned to save weight and improve performance. Weighing in about 2 lbs. lighter than last year’s model, the system is made from a mixture of aluminum and titanium. The double-walled header pipes are reshaped for reduced noise and smoother flow, and they send exhaust gasses to the single muffler that includes a catalytic converter. Yamaha says the R6 surpasses the new EU2 standards with no loss of power.
...Visually, the bike is simply stunning from any angle. Slicker-looking bodywork with new “engine revealing side cowls” and a more compact tail section compliment the Gatling beam multi-reflector headlights. The net result of all these changes is improved aerodynamics as well as looking mighty fine. Wind protection is not too bad, with most of the blast being taken square in the chest, which on the highway took some pressure off my wrists and shoulders. Get into a tuck and the wind goes clean over you, with the mechanical symphony being played out underneath your chest being the dominant sound.
...The view from the cockpit is clean and uncluttered, and the instrument control panel is very compact and efficient. The white-faced tachometer is augmented by a shift light that lets you know it is time to select another gear when it lights up at 14,250rpm. The shift lift can be set anywhere from 10k rpm's upward. The speedometer is digital and has a temperature gauge above and an odometer and tripmeter below. There are a couple of trip options available. Below the gauges is a row of warning lights, and the whole aray gives off a warm glow at night. The view from the mirrors is typical of a sport-orientated bike, so it's necessary tuck in an elbow to get a good look behind.
...Acceleration in top gear is quick if not rapid, but once over the legal limit the little 6 takes off like a scalded cat without so much as a downshift. Drop to second at this speed and you will find yourself looking at the sky. Around town, you can run the rpm as low as you like, and the perfect fuel injection will let you open the throttle anywhere, anytime, without missing a beat. Of course, every thing starts happening a lot quicker once you pass 8000 rpm, and the bike pulls hard till redline.
...The footpegs are now 5mm further forward for better weight distribution to the front end. They are certainly high and the bars are low, but found the overall ride package a lot more comfortable than expected.
...The new R6 is 8 lb lighter, more powerful and better looking while still being listed the same $7999. It's definitely a better bike than its predecessor, but it has some stiff competition. The ultimate winner can't be decided until we ride these things back to back, which will have to wait until our 600 shootout. Nothing I have ridden can be so mercilessly thrown into corners with such confidence, and nothing I have ridden has left me so badly wanting more.
Yamaha Design Cafe
...The all-new YZF-R6 begins with a radical new DeltaBox III frame. The first street motorcycle ever to use our new Controlled Filling Die Casting technique, resulting in a lighter aluminum chassis that is stiffer. What once took 16 welds now requires two. Revisions to the steering head give even greater feedback. And a 10mm longer swingarm and repositioned swingarm pivot improve traction.
...New five-spoke wheels reduce unsprung weight by making hub and spokes a single structural unit. The new casting technique makes the rim lighter.
...The ultra-compact, lightweight, 600cc, DOHC, 16-valve, liquid-cooled in-line four-cylinder engine puts out over 200 horsepower per liter. The engine retains its long-stroke dimensions for excellent midrange torque, but over 90% of its parts are stronger or lighter, including the new forged pistons and the new sleeveless cylinders.
...The second-generation R6 benefits from the addition of the same type of suction-piston fuel injection as the R1. The R6's utilizes a larger pressurized airbox, bigger throttle bodies, and resculpted intake ports, giving unsurpassed throttle response.
...New dual Gatling beam multi-reflector headlights produce bright, even lighting, and are enclosed in a redesigned fairing for superb aerodynamics.
...The result of all these changes is more power, less weight (now 8 lbs. lighter).
03 R6 New Features
...Ninety percent of the engine parts have been changed.
...Competition-bred suction-piston fuel injection (similar to the R1), features short intake ports and a special vacuum-controlled intake system to ensure instant throttle response all the way up to the incredible 15,500-rpm redline.
...Direct ignition coils, iridium spark plugs and high-output magneto deliver reliable firing.
...Curved radiator provides 30% greater engine cooling efficiency.
...4-into-2-into-1 exhaust optimizes engine performance, and now for 2003, the use of titanium and aluminum reduces overall weight.
...Radical new Deltabox IlI aluminum chassis that's 50% stiffer.
...Controlled Filling Die Casting (CF casting) is used to produce an incredibly sleek swingarm that is remarkably strong and light by pinpointing exactly where material needs to be. Pivot position and swingarm length (576mm) are optimized for even greater traction feel.
...Removable rear subframe uses new CF casting technology for lighter weight.
...Five-spoke 17" wheels both front and rear reduce unsprung weight by making hub and spokes a single structural unit. A new casting technique makes the rim section substantially lighter.
...Ultra-sleek bodywork features a sharper front profile with Ram Air duct, engine-revealing side cowlings and ultra-sleek tail section.
...Narrow 4.5-gallon fuel tank provides excellent rider ergonomics and aggressive seating position.
...Dual Gatling beam 60/55-watt multi-reflector headlight features a sleek profile for superb aerodynamics and visibility.
...Dual-bulb LED taillight design reduces both weight and size while providing excellent visibility and a sleek profile.
...8 lbs. lighter than last year's model.
...Ultra-compact, lightweight, 600cc, DOHC, 16-valve, liquid-cooled in-line four-cylinder engine puts out over 200 horsepower per liter!
...Specially designed, one-piece cylinder and crankcase assembly provides superior engine rigidity and light weight.
...Engine is a fully stressed chassis member to allow for a super-light frame design.
...Compact slant-block engine design uses stacked gearbox shafts to create a low center of gravity and balanced weight distribution.
...Lightweight forged pistons feature carburized connecting rods for superb strength and reduced reciprocating mass.
...Patented electroplated cylinder bores mean greater heat dissipation for consistent power delivery and reduced frictional power loss.
...Close-ratio 6-speed transmission delivers seamless power and maximum acceleration.
...Compact, large-capacity clutch ensures consistent, fade-free performance.
...Ram Air Induction System delivers cool, high-pressure air for optimal combustion and greater horsepower at high speed.
...Hollow side-driven camshafts with specially designed valve lifters and computer-perfected timing helps create narrow engine width.
...Large-capacity internal water pump and separate liquid-cooled oil cooler ensures optimal engine cooling efficiency.
...Fully adjustable (preload, compression and rebound damping) 43mm telescopic front fork with 4.7" of travel offers race-bred suspension performance with ultra-precise rider feedback.
...Fully adjustable (preload, compression and rebound damping) piggyback rear shock with 4.7" of travel delivers exceptional rear wheel tracking and stability. |
...Dual 298mm front disc brakes with one-piece 4-piston calipers and 220mm rear disc brake with dual-piston caliper provide outstanding stopping power.
...5-way adjustable front brake lever.
...120/60-ZR17 front and 180/55-ZR17 rear radials deliver race-spec grip.
...Durable, lightweight, aluminum clip-on bars provide optimal vibration damping.
...Multi-function digital and analog instrumentation with LED illumination features: digital speedometer, analog tachometer, dual tripmeters with odometer, upward-counting fuel reserve meter, water temp gauge and lights for neutral, high beam, low fuel and turn signals.
...Standard toolkit located in convenient storage compartment under passenger seat.
Three More Horsepower, Eight Pounds Lighter, And Fuel Injection Make The
R6 a Top Contender For the 600cc Class Crown
...In 1999 Yamaha marketed the original R6, the world's first 200-horsepower-per-liter production engine, in a cutting-edge chassis. Light, agile, and revvable beyond 15,000 rpm the R^ was named 2001 Bike of the Year by Sport Rider magazine. For 2003, the R6 has undergone nearly a total redesign, with a stronger, cleaner, fuel-injected engine, a revolutionary frame utilizing new casting technology--and a stunningly modern look from the point of its exclusive Gatling-beam headlights to the tip of its LED taillight.
Stiffer Is Better, the trademark of the Deltabox III Frame:
...Fantastic handling has always been the trademark of the R6 and racing teaches that handling begins with frame rigidity. A more efficient vacuum-assisted aluminum casting technique produces a purer, stronger frame, subframe, swingarm and wheels.
...The R6's all new Deltabox III has 50 percent greater lateral frame rigidity than before--and approaches that of the R7 Superbike frame.
..."Controlled filling aluminum die casting" technology (CF) allows the new frame to be made entirely of aluminum castings--a mass-production first--and from far fewer frame components than before. Where the previous frame required 16 welds, the new bike needs only two. Greater casting precision also allows more rigid engine mounting.
...In place of adjustable forward engine mounts, the new frame uses direct mounts, which further increase chassis stiffness and enhance feedback.
Strong Arm Tactics, the new swingarm:
...CF die casting is used again in the new swingarm, making possible a lighter arm that's also stiffer. CF simply allows placement of more material where it's needed, less where it is not needed.
...Sections of the swingarm are as thin as 2.5 millimeters. For greater traction and feel, the new swingarm is 10mm longer.
...The offset between the countershaft axis and swingarm pivot axis has been reduced from 96 to 86mm.
...Wheelbase remains a quick-turning 53.4 inches.
...Fork offset has been reduced 5mm, to 35mm, for lighter-feeling, more communicative steering.
...Functional and stylistic design aspects were considered in unison. That means the new frame looks as radical and good at the same time.
Hello Fuel Injection, Good-bye Jets :
...The same successful "suction-piston" type fuel injection introduced last season on the R1 gives the new R6 the same feeling of excellent, smooth carburetion--along with the reliability and response of electronic control.
...Throttle bodies of 38mm diameter replace the 37mm carburetors, and are fed pressurized air through a larger airbox and intake optimized to work with the new injection system.
More Power from the 03 R6 engine:
...Rather than go the traditional route--more peak power via bigger bores and shorter stroke, Yamaha engineers wanted more power but not at the expense of the excellent midrange response and lively feel of its "long-stroke" engine.
...Development concentrated on improved intake efficiency, plus reduced pumping and friction losses to extract three more horsepower- 123(with ram-air)--at the same 13,000 rpm as before, with a second power curve beginning at 8000 rpm.
...Higher-lift cams, with less overlap (made possible by fuel injection) further enhance the R6's strong midrange throttle response. Though engine dimensions, compression ratio and combustion chamber shape are unchanged, 90 percent of the engine parts are new.
Linerless Direct-Plated Cylinder:
...Breakthroughs in die-casting now allow production of an upper crankcase/ cylinder block with greatly reduced oxides in the molecular matrix. This produces a much stronger, more consistent cylinder, to which ceramic composite plating can be directly applied, instead of to a cast-in sleeve as before.
...Benefits include better heat dissipation and a more exact cylinder shape. Combined with stronger, forged pistons and redesigned rings, the new engine enjoys better gas seal and greater piston stability.
...Other engine changes include reshaped transmission gears and journals for improved shifting, an aluminum oil cooler, increased engine cooling capacity, and rare-earth magnets for a lighter flywheel.
...Once fuel is burned, a catalyzer and air induction system in the exhaust let the new R6 pass the stringent EU2 emissions standard by converting CO to CO2, hydrocarbons to CO2 and H2O, and Nox to N2, H2O and CO2.
...At the same time, the new exhaust system is 2.2 pounds lighter, quieter and more efficient, thanks to titanium internals with greater volume and higher flow.
R6 Characteristics from Yamaha
...cam chain tensioner for improved durability
...cylinders feature a ''sleeveless'' design, with the ceramic composite coating is applied directly to the aluminum bore improving the roundness accuracy and heat dissipation
...suction piston-type fuel injection system with 38mm throttle bodies
...fuel injectors are a compact design to reduce weight. They feature 4-spray holes per each injector
...high capacity airbox is increased from 7.3 to 7.6 litters for improved intake efficiency
...curved radiator uses a new ring type cooling fan. Air flow is increased by 30%
...flywheel magneto (with rare earth magnets) is lighter and produces higher output.
...ECU / igniter to match new fuel injection system
.. 90% of the internal engine components since the 2002 R6.
...inner & outer intake valve springs to match new high lift cam.
...cylinder head assembly features coolant sensor for the FI system and new separated cam shaft holders for reduced weight.
...crankshaft improves crank balance for increased engine output, with stress on plane bearings has been decreased by 20%.
... head gasket features larger holes for improved coolant flow.
...crankcase blow-by gas passage.
...''Ram Air'' intake snorkel design optimizes intake efficiency for maximum power.
...sequential ignition system features new coils for each cylinder. The spark is faster and more intense for better combustion efficiency.
...4 into 2 into1 exhaust system uses stainless steel header pipes, numerous titanium internal muffler parts and aluminum wrapping on the muffler. The revised muffler also contains a new 3-way catalyzer which meets the strict new EU-2 European emission standards.
...AI (air induction system …not ram air) is controlled by the ECU, further reducing emissions for EU-2 compliance
...lightweight oil cooler increases cooling capacity by 20% while reducing weight by 45% versus last year’s part
...primary gear allows more oil inside the clutch boss for improved lubrication and more consistent clutch action
...transmission uses thicker 3rd & 4th gears (teeth size increased by 0.4mm) and new more precise splines on the drive axle and gears.
...gears now utilize 5 dogs instead of 3 and dog shape has been modified for better contact. The result is better shifting feel and more positive engagement
...rotating inertia of the shift drum has been increased by 13% and the diameter of the stopper roller has been increased to 16mm for improved shift feeling
...lightweight Deltabox III chassis features new CF aluminum die-casting on the rear bolt-on section of the frame. Welding points have been reduced from 16 to 2 using this new method. The engine mounting system has also been revised. Torsional rigidity is increased by approx. 50%
...distance between the centre of the drive sprocket and the swingarm pivot point has been reduce by 10mm for improved traction.
...rear swingarm also features the new CF die casting method. The span between the swingarm pivot point and the rear axle has been increased by 10mm. It is more rigid the past version.
...fuel tank houses an in-tank fuel pump. The design of the tank has been modified for improved rider mobility
...top triple clamp features a 5mm reduction in fork offset for improved handling
...lightweight 5-spoke lightweight wheels (frt. = MT3.50x17 / rear = MT5.5x17) reduce weight and provide lighter handling than previously.
...rear shock linkages are made of aluminum to reduce weight
...''Gatling'' style headlights produce a wide spread of light while using less energy. Each headlight contains two lenses that distribute light coming from a 55W bulb. As well as being able to produce the same brightness from a smaller wattage than conventional designs, the gatling beam headlight also offers a more even distribution of light.
...flexible, compact turn signals are similar to those used on the 2002 R1
...complementing the aggressive new headlight assembly is a new LED taillight featuring new-shaped lenses and weighing 55% less than the '02 unit.
...R1 inspired instrumentation features a programmable shift light, analog tach, digital speedo, water temp gauge, odometer and tripmeters
...fully adjustable 43mm cartridge style forks. Adjustments include prelude, compression and rebound damping
...floating front disc brakes use 298mm discs with 7 pins to float on (down from 10) and 5 mounting points down from 6
...front disc brake pads feature sinter material. The backing plate has been eliminated
...fully adjustable piggy-back style rear shock features new lightweight aluminum collars and a special low friction internal piston for smooth operation. The overall weight of the shock assembly has been reduced.
...rear 220mm disc utilizes 5 fixing points instead of 6 * New premium Dunlop 208 radial tires
...regulator / rectifier has increased in size for improved heat dissipation
...handlebar switches provide a quality image
...re-styled lightweight LED taillight assembly
2003 YZF-R6, more Yamaha information:
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