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Discussion Starter #1 (Edited)
Oscar - 2001 R6 Rebuild Log

Hi,

Yesterday I bought a 2001 YZF-R6. It starts and idles, but has bad hesitation and will need some work before being out on the road.

It has:
  • Aftermarket exhaust
  • Dynojet carb kit
  • Rear frame extenders
It needs:
  • New front brake master cylinder reservoir
  • Repaired engine mount
  • Carb work
  • New foot pegs
  • New gas tank




Previous owner said it fell off a trailer.. Hence the damage.
 

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Fill it with wires!
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Discussion Starter #2
I tried changing the thread title to name the bike Oscar but it either didn't work or hasn't updated.

I took Carb #1 apart and it was really clean and looked properly assembled, so I'm thinking the hesitation may be due to the lack of an air filter and the unconnected vacuum lines off the carb. I'm going to go through and clean and check each of them, then see if just installing them properly fixes the issue.



 

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Fill it with wires!
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Discussion Starter #3
The new brake parts arrived today!

The replacement connection kit fit great, but I couldn't get the reservoir mounted in a way that worked well.



 

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Fill it with wires!
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Discussion Starter #4
New air filter arrived today.. in an opened package. It has poor fitment and extra mold rubber I had to trim. I think I just got sold an engineering sample.

I took the last three carburetors apart, and accidentally broke one of the coolant couplings. Yikes, they're $50 from bikebandit :-/

I also took the brake caliper off to flush it, but noticed 1) one of the pads is almost spend, and 2) there's mounts for a mirrored caliper and disk on the other side... Do 2001 R6's have dual front brakes? If so, I wonder why mine doesn't.

Man, these brake pads are tiny!

 

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there's mounts for a mirrored caliper and disk on the other side... Do 2001 R6's have dual front brakes? If so, I wonder why mine doesn't.
Yes, all R6s have dual front brakes. One of the prior owners must have removed. Get a Yamaha or Haynes or Clymer manual, will save you some time and headaches.
Front brake reservoir hose looks long, might be why problematic mounting. Have fun with the build.

https://www.mrcycles.com/oemparts/a/yam/50044796f8700209bc78fe78/front-master-cylinder
 

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Discussion Starter #6
Thanks oldbonez.

I double checked the manual I found online, and it only shows disassembly for the left side, but does show two hydraulic hoses attached to the master cylinder. I guess I'll keep my eyes open for a right hand side caliper/disk.
 

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Fill it with wires!
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Discussion Starter #9
why do i need 5 post to see pics?
I dunno man. It's like visiting the wise man on the mountain, some things are only apparent after enough engagement with the topic at hand.

We'll get you sorted though. Do you have a bike? How's the weather over there?
 

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I dunno man. It's like visiting the wise man on the mountain, some things are only apparent after enough engagement with the topic at hand.

We'll get you sorted though. Do you have a bike? How's the weather over there?
I do bro I got an 5EB just like you, doing a similiar rebuild, will be posting a thread soon. Stay tuned!
 

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Discussion Starter #13 (Edited)
Finished rebuilding the carbs!

Replaced the spark plugs, just for good measure.

Then I lost the key for a few days, finally found it hiding on a keychain I'd looked at a dozen times...

While hooking the carbs back up I noticed that the coolant to the carbs has been bypassed, and most of the EGR / emissions vacuum pieces are gone.

OK, carbs are back on the bike, and it runs! Kinda..

I took it down the street and back when I first got it, and there wasn't a problem. But after reinstalling the carbs the bike will start, and then immediately die when I put it in gear. I tracked the issue down to the Starting Circuit Cutoff Relay box, and after finding that they're $100 to replace, I cut this one open. It looks like some of the diodes went bad. They should be easy enough to replace; does anyone know where I can find similar ones to swap in?

** edit: I also noticed that the voltage rectifier has been replaced.. That likely has something to do with the fried diodes, right?

When I measure between the "Sky Blue" and "Blue/Yellow" or "Sky Blue" and "Black/Yellow" wires I get either no connection (against the diode) or something around 11 MOhms (with the diode). Pretty sure they're shot.



 

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Fill it with wires!
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Discussion Starter #14
Found a faulty diode (D8) on the relay board and replaced it with a 1N4007. That fixed it!

While trying to start the bike though, I noticed gas had filled the crankcase... So the carbs are leaking, which sucks because turning off the petcock on the tank is a huge pain.

Now that I'm back on track, I still need to figure out what the next steps are for tuning and getting the carbs and engine back to 100%

Also, I noticed that the new brake reservoir line was sweating the oil out.... Does anyone have a suggestion on what I should get to replace it?
 

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Fill it with wires!
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Discussion Starter #15
Bought some parts

- Front brake reservoir and line
- Front righthand brake caliper, line, rotor, and bolts
- Fork rebuild kit
- Bar end mirror

While that's all shipping I need to get back out there and pull the carbs one last time to find which one is leaking and then fix it.
 

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Discussion Starter #16
Took the bike out for a spin just now. At around 35 mph the engine starts fluttering and faltering. Possibly a fuel delivery issue?
 

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Discussion Starter #17
I wrote this whole post and it didn't submit :-/

OK. I've had the carbs off for a while as I tried to fix the gas leak. Carb #1 still leaks, even after I replaced the float valve with a new one. It sucks, for now I'm just turning off the petcock.

Today I rebuilt the front forks with new bearings, seals, and oil. I don't know how to adjust them. Will have to look into that. I accidentally left the top washer out of the left hand one, and I don't know how to get just the oil seal back out to install it without another full teardown.

While putting the front end back together I discovered that the previous owner had installed the wheel backwards! With that fixed the left hand brake caliper "just fits" without needed those random washers offsetting it. I'm now waiting on a double banjo bolt before I can install the new right hand caliper.
 

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Fill it with wires!
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Discussion Starter #18
Took the bike back out today. Again, at about half throttle the engine just bogs down and threatens to quit.

I'm going to borrow a friend's sync gauge set and try to check if the carbs are in sync.
 

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Discussion Starter #19
Bought new vacuum line for the gauges, but was informed to do a valve clearance check first, and only after that sync the carbs.

I got the valve cover off and it looks like the intake valve are all in spec (0.1mm gauge fits) but the exhaust valves are not (0.2mm gauge sticks). I'm not sure how to tell if the gauge is feeling resistance because of the clearance between the valve and cam, or because the gauge has to bend past the edge of the engine in order to get in there..
 

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