Casting technique could save 8kg on new R6

More details have emerged about Yamaha’s newly-invented casting technique (as revealed on this site on February 7) which suggest it could save up to 8kg on the weight of a 600cc sports bike.

The technique can’t be used for engine internals (so won’t make any big impression on speed of revving and, therefore, power) but it does produce casings that are up to 30 per cent lighter.

Engine experts believe that could result in at least an 8kg (17.6lb) saving on next year’s updated R6, for example and the firm’s main bike factory in Iwata, Japan, is already gearing up to introduce the new production method on 2003 models.

The process works by creating a vacuum in the mould before molten aluminium pours in. This allows a thinner and more even flow of metal than conventional casting techniques.

Where current aluminium cases have to be 2.5mm thick to account for imperfections, Yamaha can now cut that to 1.5mm, saving weight and have the same strength.

The vacuum-casting process isn’t new in itself – it’s been used in hand-built Formula One car engines for a quarter of a century. But the process has never before been used for mass production because of problems with the reliability of the seals.

Yamaha has overcome this problem but isn’t revealing how. The technology is up for sale to rivals.

Yamaha UK spokesman Dan Harris said: ” The plan is to use the technique on every new bike within a year. This will be for new models at the moment, rather than tooling up to use it on existing machines. ”