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  1. #1
    I JET (OP)
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    R6 Cams, Head gasket, headers, here we go

    The time has come, I've been wanting to tackle this project for a long time. To many personal road blocks meant the cup bike has sat in storage for the past 3 years. I've recently starting prepping the bike. I want to get back to regular track days.

    The last time I posted, I had test fit the R6 headers and was looking at link pipe options. Luckily I was able to use the GYTR undertail muffler turned on its side and a section of the GYTR mid pipe to make up the link.. You can see I have started to make a template for the muffler hanger (progress)





    I purchased the R6 cams from a member on here a few years back.



    They came with these new YEC cam gears.



    New head gasket for a 2003-2005 R6. Part no. 5SL-11181-00-00.
    The R6 head gasket is thinner and will raise the compression ratio from 12.1 to 12.4



    From what I've researched, this has been done before, the cam swap at least. The results sounded promising but also read some complaints of a flat spot in the rev range. Without proper fuel mapping its hard to say for sure what the issue was in those cases. People will always argue to just buy an R6 to start with but for me this is more of a hobby.

    My method of attacking this will be:

    1. Strip down and measure current valve clearances
    2. Remove stock cams, remove head, replace head gasket
    3. Install head, install R6 cams and set to standard timing marks
    4. Re-measure valve clearances and adjust if necessary to R6 spec
    5. Degree cam shafts to 102° ILC and 105°ELC (open to suggestions here and very much still researching but from what I've read this appears to be a good starting point)
    6. Re-assembly and test run engine
    7. Advance timing via trigger wheel modification (thanks final impact) 5-6° advanced over stock seems to be the sweet spot
    8. Custom fuel map

    At some point in there i'll be doing oil, filter and plugs, still need to decide still on which spark plugs to use, CR10EK or CR10E.
    I do have some ideas for improving the air intake tract but they will come later on.
    Will update thread as things progress.

    DYNO Results --> https://www.600riders.com/forum/fz6-...tml#post636645

    Converted back to Street bike --> https://www.600riders.com/forum/fz6-...tml#post637841
    Last edited by I JET; 07-04-2018 at 05:41 PM.
    I JET

    1991 Yamaha 50
    1989 Yamaha 80
    1989 Honda XR80
    1988 Honda XR100
    1993 Honda XR250
    1997 Honda XR400
    2007 KTM 450 EXC
    1994 Honda RVF 400
    2010 BMW S1000RR
    2010 Triumph 1050 Speed Triple
    2012 BMW S1000RR
    2013 KTM 1190 Adventure
    2014 KTM 1290 SuperdukeR
    current bikes
    2010 KTM 990 Supermoto
    2014 MV Agusta Rivale 800
    2007 Yamaha FZ6 Cup Race Bike

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  3. #2
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    Re: R6 Cams, Head gasket, headers, here we go

    Bike looks very good in that color combo.
    About the cams, why not fit adjustable sprockets?
    2004 FZ6 with R6 Fork and brakes, Leo Vince SBK Carbon Exhaust, Venhill SS Race brake lines

  4. #3
    I JET (OP)
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    Re: R6 Cams, Head gasket, headers, here we go

    At first I thought they were adjustable but after reading the YEC manual it states 'by making the assembly holes of the cam sprocket long, valve timing can be adjusted' So by elongating the holes they become adjustable.

    From the YEC manual-

    I JET

    1991 Yamaha 50
    1989 Yamaha 80
    1989 Honda XR80
    1988 Honda XR100
    1993 Honda XR250
    1997 Honda XR400
    2007 KTM 450 EXC
    1994 Honda RVF 400
    2010 BMW S1000RR
    2010 Triumph 1050 Speed Triple
    2012 BMW S1000RR
    2013 KTM 1190 Adventure
    2014 KTM 1290 SuperdukeR
    current bikes
    2010 KTM 990 Supermoto
    2014 MV Agusta Rivale 800
    2007 Yamaha FZ6 Cup Race Bike

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  6. #4
    2 Da Street, Knobs R Gone FinalImpact's Avatar
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    Re: R6 Cams, Head gasket, headers, here we go

    Good to hear from you again...
    That extra compression also takes away valve clearance moving them closer to the pistons. One concern here is with the added lift of the intake lobe you have lost more clearance which is not a show stopper but needs verified.
    Likely the only time you would get into trouble is missed shift where the valves could float.

    Rig up a dial indicator to both pairs of valves (separately) and verify how much clearance you have at TDC by pushing the stem down with your hand until it hits the piston. Without looking IDR the number but it seemed 0.040" or something like that.

    I would check the intake and exhaust before tear down.

    Also, with the head off, take few minutes and massage the intake port at the TB for smooth transition. The intake passage doesn't need to be larger or polished, just aligned and free of bumps imposing a reversion. The exhaust you could polish, it can reduce heat transfer into the head.

    As for the ignition advance, as simple as it is, it will make wake the engine up. Obviously you'll use the higher grade of petrol (likely doing that now)... All of these combined should make her pull pretty well! She won't seem like the same bike.

    The tracks you run, do you get into tight corners, below 3rd gear?
    08 Raven w/a few mods...
    R6 Forks, R1 Rear Shock (revalved), 6° Ignition Advance, S1 CAT free Header, SS Mid-Pipe, 2Bro Exhaust, AIS block off plates, Bazzaz Z-Fi Fuel Controller & Z-AFM Data Logger, Air Box mod, CR10E Plugs, 48-Tooth Rear Sprocket, FZ1 Bars, Spider Grips, Adj levers, Powder Coated -Triple, Bars & Rear Sets, Solid mounted rear-sets w/knurled pegs, Dual Headlight, Tail Tidy, LED Combo Brake & Directionals, LED POD lights & Tinted PUIG Wind Screen!

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    I JET (OP)
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    Re: R6 Cams, Head gasket, headers, here we go

    Thanks for the tips @FinalImpact.
    Will check valve to piston clearance before and after as you recommended and report back. Given the same components make up the R6 donk, I agree it should not be a show stopper but worth confirming.

    Will also spend some time dressing up the ports as you said, I've seen first hand how far off the transition can be to the manifolds.

    As for the ignition timing, correct, already using 98 RON pump fuel from Shell or BP which is our highest readily available premium pump fuel. Just ordered a set of CR10E plugs too.
    There's currently two local tracks, I have gearing to suit both. The slower, tighter track has only one low speed 2nd gear corner (60kph), the rest is pretty flowing.
    I JET

    1991 Yamaha 50
    1989 Yamaha 80
    1989 Honda XR80
    1988 Honda XR100
    1993 Honda XR250
    1997 Honda XR400
    2007 KTM 450 EXC
    1994 Honda RVF 400
    2010 BMW S1000RR
    2010 Triumph 1050 Speed Triple
    2012 BMW S1000RR
    2013 KTM 1190 Adventure
    2014 KTM 1290 SuperdukeR
    current bikes
    2010 KTM 990 Supermoto
    2014 MV Agusta Rivale 800
    2007 Yamaha FZ6 Cup Race Bike

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    I JET (OP)
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    Re: R6 Cams, Head gasket, headers, here we go

    Progress









    I JET

    1991 Yamaha 50
    1989 Yamaha 80
    1989 Honda XR80
    1988 Honda XR100
    1993 Honda XR250
    1997 Honda XR400
    2007 KTM 450 EXC
    1994 Honda RVF 400
    2010 BMW S1000RR
    2010 Triumph 1050 Speed Triple
    2012 BMW S1000RR
    2013 KTM 1190 Adventure
    2014 KTM 1290 SuperdukeR
    current bikes
    2010 KTM 990 Supermoto
    2014 MV Agusta Rivale 800
    2007 Yamaha FZ6 Cup Race Bike

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    I JET (OP)
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    Re: R6 Cams, Head gasket, headers, here we go











    Just stopped now for lunch. By end of today I plan to have the head back on, new cams in and timed up to standard marks. Tomorrow I'll check the valve clearances and begin degreeing the cams.
    I JET

    1991 Yamaha 50
    1989 Yamaha 80
    1989 Honda XR80
    1988 Honda XR100
    1993 Honda XR250
    1997 Honda XR400
    2007 KTM 450 EXC
    1994 Honda RVF 400
    2010 BMW S1000RR
    2010 Triumph 1050 Speed Triple
    2012 BMW S1000RR
    2013 KTM 1190 Adventure
    2014 KTM 1290 SuperdukeR
    current bikes
    2010 KTM 990 Supermoto
    2014 MV Agusta Rivale 800
    2007 Yamaha FZ6 Cup Race Bike

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  13. #8
    I JET (OP)
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    Re: R6 Cams, Head gasket, headers, here we go







    I JET

    1991 Yamaha 50
    1989 Yamaha 80
    1989 Honda XR80
    1988 Honda XR100
    1993 Honda XR250
    1997 Honda XR400
    2007 KTM 450 EXC
    1994 Honda RVF 400
    2010 BMW S1000RR
    2010 Triumph 1050 Speed Triple
    2012 BMW S1000RR
    2013 KTM 1190 Adventure
    2014 KTM 1290 SuperdukeR
    current bikes
    2010 KTM 990 Supermoto
    2014 MV Agusta Rivale 800
    2007 Yamaha FZ6 Cup Race Bike

  14. Thanks FinalImpact thanked for this post
  15. #9
    I JET (OP)
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    Re: R6 Cams, Head gasket, headers, here we go

    Didn't quite get there today, new head gasket on, Head on and torqued down, cam chain and guides back in ready to receive cams. Will continue with it tomorrow. Over all the cylinder bores look very good and all the valve clearances were within spec. The bike had 2600kms on the clock when I got it but I thought the speedo had been changed, starting to think the kms were accurate.
    I JET

    1991 Yamaha 50
    1989 Yamaha 80
    1989 Honda XR80
    1988 Honda XR100
    1993 Honda XR250
    1997 Honda XR400
    2007 KTM 450 EXC
    1994 Honda RVF 400
    2010 BMW S1000RR
    2010 Triumph 1050 Speed Triple
    2012 BMW S1000RR
    2013 KTM 1190 Adventure
    2014 KTM 1290 SuperdukeR
    current bikes
    2010 KTM 990 Supermoto
    2014 MV Agusta Rivale 800
    2007 Yamaha FZ6 Cup Race Bike

  16. #10
    2007 FZ6 TownsendsFJR1300's Avatar
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    Re: R6 Cams, Head gasket, headers, here we go

    What's that big round thing under the intake by cylinders 1 & 2? I don't remember seeing that on an FZ head....

    How are you going to check valve to piston gap (with valves OPEN), Silly putty, ?


    BTW, the top of the engine looks really good, Very little carbon, crosshatching looks great..


    .

 

 
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