Yamaha YZF-R1 2000 Service manual

Yamaha YZF-R1 2000 Service manual
FOREWORD
This Supplementary Service Manual has been prepared to introduce new service and data for the
YZF-R1 2000. For complete service information procedures it is necessary to use this Supplementary
Service Manual together with the following manual.
YZF-R1 SERVICE MANUAL: 4XV1-AE1
YZF-R1 2000
SUPPLEMENTARY
SERVICE MANUAL
1999 by Yamaha Motor Co., Ltd.
First Edition, December 1999
Any reproduction or unauthorized use
without the written permission of
Yamaha Motor Co., Ltd. is expressly
prohibited.
EB001000
NOTICE
This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha dealers
and their qualified mechanics. it is not possible to include all the knowledge of a mechanic in one manual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles
should have a basic understanding of mechanics and the techniques to repair these types of vehicles.
Repair and maintenance work attempted by anyone without this knowledge is likely to render the vehicle unsafe and unfit for use.
Yamaha Motor Company, Ltd. is continually striving to improve all of its models. Modifications and significant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers
and will appear in future editions of this manual where applicable.
NOTE:
Designs and specifications are subject to change without notice.
EB002000
IMPORTANT MANUAL INFORMATION
Particularly important information is distinguished in this manual by the following.
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR
SAFETY IS INVOLVED!
WARNING
CAUTION:
NOTE:
Failure to follow WARNING instructions could result in severe injury or death to
the motorcycle operator, a bystander or a person checking or repairing the motorcycle.
A CAUTION indicates special precautions that must be taken to avoid damage
to the motorcycle.
A NOTE provides key information to make procedures easier or clearer.
EB003000
HOW TO USE THIS MANUAL
This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive
explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid
out with the individual steps in sequential order.
1 The manual is divided into chapters. An abbreviation and symbol in the upper right corner of each
page indicate the current chapter.
Refer to “SYMBOLS”.
2 Each chapter is divided into sections. The current section title is shown at the top of each page,
except in Chapter 3 (“PERIODIC CHECKS AND ADJUSTMENTS”), where the sub-section title(-s) appears.
3 Sub-section titles appear in smaller print than the section title.
4 To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each
removal and disassembly section.
5 Numbers are given in the order of the jobs in the exploded diagram. A circled number indicates a
disassembly step.
6 Symbols indicate parts to be lubricated or replaced.
Refer to “SYMBOLS”.
7 A job instruction chart accompanies the exploded diagram, providing the order of jobs, names of
parts, notes in jobs, etc.
8 Jobs requiring more information (such as special tools and technical data) are described sequentially.
6
2
1
3
4
5
8
7
EB004000
1
2
GEN
INFO
SYMBOLS
SPEC
3
4
CHK
ADJ
ENG
5
6
COOL
CARB
7
8
CHAS
General information
Specifications
Periodic checks and adjustments
Engine
Cooling system
Carburetor(-s)
Chassis
Electrical system
Troubleshooting
Symbols 10 to 17 indicate the following.
10
10
11
12
13
14
15
16
17
TRBL
SHTG
11
12
13
14
15
16
17
18
19
20
24
1
2
3
4
5
6
7
8
9
ELEC
9
21
The following symbols are not relevant to every
vehicle.
Symbols 1 to 9 indicate the subject of each
chapter.
22
23
25
Serviceable with engine mounted
Filling fluid
Lubricant
Special tool
Tightening torque
Wear limit, clearance
Engine speed
Electrical data
Symbols 18 to 23 in the exploded diagrams indicate the types of lubricants and lubrication
points.
18
19
20
21
22
23
Engine oil
Gear oil
Molybdenum disulfide oil
Wheel bearing grease
Lithium soap base grease
Molybdenum disulfide grease
Symbols 24 to 25 in the exploded diagrams indicate the following.
24 Apply locking agent (LOCTITE)
25 Replace the part
CONTENTS
SPECIFICATIONS
GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHASSIS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ELECTRICAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . . . . . . .
CHASSIS TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . . . . .
LUBRICATION POINTS AND LUBRICANT TYPES . . . . . . . . . . . . .
ENGINE LUBRICATION POINTS AND LUBRICANT TYPES . .
OIL FLOW DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
COOLANT FLOW DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CABLE ROUTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
2
6
9
11
11
12
13
13
14
17
20
PERIODIC CHECKS AND ADJUSTMENTS
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PERIODIC MAINTENANCE AND LUBRICATION INTERVALS . . .
COWLINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AIR FILTER CASE AND IGNITION COIL PLATE . . . . . . . . . . . . . . .
33
33
35
36
OVERHAULING THE ENGINE
AIR INDUCTION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ASSEMBLING THE CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . . .
37
38
39
40
41
43
COOLING SYSTEM
RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
CARBURETORS
AIR INDUCTION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AIR INJECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AIR CUTOFF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AIR INDUCTION SYSTEM DIAGRAMS . . . . . . . . . . . . . . . . . . . . .
CHECKING THE AIR INDUCTION SYSTEM . . . . . . . . . . . . . . . .
47
47
47
48
49
CHASSIS
FRONT WHEEL AND BRAKE DISCS . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE FRONT WHEEL . . . . . . . . . . . . . . . . . . . . . . . .
FRONT AND REAR BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REAR BRAKE MASTER CYLINDER AND BRAKE
FLUID RESERVOIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
50
51
52
52
ELECTRICAL
INSTRUMENT FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INDICATOR LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
COOLANT TEMPERATURE WARNING LIGHT . . . . . . . . . . . . . .
SPEEDOMETER UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ELECTRIC STARTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STARTER MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SELF-DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
YZF-R1 WIRING DIAGRAM (For EUR)
YZF-R1 WIRING DIAGRAM (For OCE)
53
53
54
55
57
57
62
62
63
66
67
GENERAL SPECIFICATIONS
SPEC
SPECIFICATIONS
GENERAL SPECIFICATIONS
Item
Dimensions
Overall length
Overall width
Overall height
Seat height
Wheelbase
Minimum ground clearance
Minimum turning radius
Weight
Wet (with oil and a full fuel tank)
Dry (without oil and fuel)
Maximum load (total of cargo, rider,
passenger, and accessories)
Standard
Limit
2,035 mm
2,095 mm (for AUS)
695 mm
1,105 mm
815 mm
1,395 mm
140 mm
3,400 mm
194 kg
175 kg
201 kg
–1–
ENGINE SPECIFICATIONS
SPEC
ENGINE SPECIFICATIONS
Item
Engine
Engine type
Displacement
Cylinder arrangement
Bore stroke
Compression ratio
Engine idling speed
Vacuum pressure at engine idling
speed
Standard compression pressure
(at sea level)
Fuel
Recommended fuel
Fuel tank capacity
Total (including reserve)
Reserve only
Engine oil
Lubrication system
Recommended oil
Standard
Limit
Liquid-cooled, 4-stroke, DOHC
998 cm3
Forward-inclined parallel 4-cylinder
74 58 mm
11.8 : 1
1,000 1,100 r/min
29.3 kPa (220 mm Hg)
1,450 kPa (14.5 kgf/cm2) at 400 r/min
Regular unleaded gasoline
Unleaded fuel (for AUS)
18 L
3.8 L
Wet sump
Temp.
SAE20W40SE or SAE10W30SE
Quantity
Total amount
Without oil filter cartridge
replacement
With oil filter cartridge replacement
Oil pressure (hot)
Relief valve opening pressure
3.6 L
2.7 L
2.9 L
45 kPa at 1,100 r/min
(0.45 kgf/cm2 at 1,100 r/min)
490 570 kPa (4.9 5.7 kgf/cm2)
–2–
ENGINE SPECIFICATIONS
Item
Camshafts
Drive system
Camshaft cap inside diameter
Camshaft journal diameter
Camshaft-journal-to-camshaftcap clearance
Intake camshaft lobe dimensions
SPEC
Standard
Limit
Chain drive (right)
24.500 24.521 mm
24.459 24.472 mm
0.028 0.062 mm
Measurement A
Measurement B
Measurement C
Exhaust camshaft lobe dimensions
32.5 32.6 mm
24.95 25.05 mm
7.45 7.65 mm
32.4 mm
24.85 mm
Measurement A
Measurement B
Measurement C
Max. camshaft runout
32.95 33.05 mm
24.95 25.05 mm
7.75 7.95 mm
32.85 mm
24.85 mm
0.03 mm
–3–
ENGINE SPECIFICATIONS
Item
Standard
Valves, valve seats, valve guides
Valve clearance (cold)
Intake
Exhaust
Valve dimensions
Head Diameter
SPEC
0.11 0.20 mm
0.21 0.25 mm
Face Width
Valve head diameter A
Intake
Exhaust
Valve face width B
Intake
Exhaust
Valve seat width C
Intake
Exhaust
Valve margin thickness D
Intake
Exhaust
Valve stem diameter
Intake
Exhaust
Valve guide inside diameter
Intake
Exhaust
Valve-stem-to-valve-guide clearance
Intake
Exhaust
Valve stem runout
Valve seat width
Intake
Exhaust
Connecting rods
Crankshaft-pin-to-big-end-bearing
clearance
Bearing color code
Limit
Seat Width
Margin Thickness
22.9 23.1 mm
24.4 24.6 mm
1.76 2.90 mm
1.76 2.90 mm
0.9 1.1 mm
0.9 1.1 mm
0.5 0.9 mm
0.5 0.9 mm
3.975 3.990 mm
4.465 4.480 mm
3.945 mm
4.43 mm
4.000 4.012 mm
4.500 4.512 mm
4.05 mm
4.55 mm
0.010 0.037 mm
0.020 0.047 mm
0.08 mm
0.1 mm
0.01 mm
0.9 1.1 mm
0.9 1.1 mm
0.031 0.055 mm
–1 = Violet 0 = White 1 = Blue 2 = Black
–4–
ENGINE SPECIFICATIONS
Item
Transmission
Transmission type
Primary reduction system
Primary reduction ratio
Secondary reduction system
Secondary reduction ratio
Operation
Gear ratios
1st gear
2nd gear
3rd gear
4nd gear
5th gear
6th gear
Max. main axle runout
Max. drive axle runout
Carburetors
Model (manufacturer) quantity
Throttle cable free play (at the
flange of the throttle grip)
ID mark
Main jet
Main air jet
Jet needle
Needle jet
Pilot air jet
Pilot outlet
Pilot jet
Bypass 1
Bypass 2
Bypass 3
Pilot screw turns out
Valve seat size
SPEC
Standard
Limit
Constant mesh, 6-speed
Spur gear
68/43 (1.581)
Chain drive
43/16 (2.688)
Left-foot operation
35/14 (2.500)
35/19 (1.842)
30/20 (1.500)
28/21 (1.333)
30/25 (1.200)
29/26 (1.115)
0.08 mm
0.08 mm
BDSR40 (MIKUNI) 4
3 5 mm
5JJ1 00
#130
Carburetors 1 and 4: #60
Carburetors 2 and 3: #65
6DEY5-53-3
P-OM
#120
1.0
#15
0.8
0.9
0.8
3.125
1.5
–5–
CHASSIS SPECIFICATIONS
SPEC
CHASSIS SPECIFICATIONS
Item
Front tire
Tire type
Size
Model (manufacturer)
Tire pressure (cold)
0 90 kg
90 197 kg
High-speed riding
Min. tire tread depth
Rear tire
Tire type
Size
Model (manufacturer)
Tire pressure (cold)
0 90 kg
90 197 kg
High-speed riding
Min. tire tread depth
Rear brake
Brake type
Operation
Brake pedal position (from the top
of the brake pedal to the bottom of
the rider footrest bracket)
Recommended fluid
Brake discs
Diameter thickness
Min. thickness
Max. deflection
Brake pad lining thickness
Master cylinder inside diameter
Caliper cylinder inside diameter
Standard
Limit
Tubeless
120/70 ZR17 (58W)
MEZ3Y FRONT (METZELER)
D207FQ (DUNLOP)
250 kPa (2.5 kg/cm2, 2.5 bar)
250 kPa (2.5 kg/cm2, 2.5 bar)
250 kPa (2.5 kg/cm2, 2.5 bar)
1.6 mm
Tubeless
190/50 ZR17 (73W)
MEZ3Y (METZELER)/D207N (DUNLOP) 250 kPa (2.5 kg/cm2, 2.5 bar)
290 kPa (2.9 kg/cm2, 2.9 bar)
250 kPa (2.5 kg/cm2, 2.5 bar)
1.6 mm
Single-disc brake
Right-foot operation
35 40 mm
DOT 4
245 5 mm
5.5 mm
4.5 mm
0.1 mm
0.5 mm
12.7 mm
38.2 mm
–6–
CHASSIS SPECIFICATIONS
Item
Front suspension
Suspension type
Front fork type
Front fork travel
Spring
Free length
Spacer length
Installed length
Spring rate (K1)
Spring stroke (K1)
Optional spring available
Fork oil
Recommended oil
Quantity (each front fork leg)
Level (from the top of the inner
tube, with the inner tube fully
compressed, and without the
fork spring)
Damper adjusting rod locknut
distance
Spring preload adjusting positions
Minimum
Standard
Maximum
Rebound damping adjusting
positions
Minimum*
Standard*
Maximum*
Compression damping adjusting
positions
Minimum*
Standard*
Maximum*
*with the adjusting screw fully turned
in position
SPEC
Standard
Limit
Telescopic fork
Coil spring/oil damper
135 mm
255 mm
85 mm
242.4 mm
7.35 N/mm (0.75 kgf/mm)
0 135 mm
No
Suspension oil “01” or equivalent
482 cm3
74 mm
11 mm
8
6
1
11
5
1
9
5
1
–7–
CHASSIS SPECIFICATIONS
Item
Rear suspension
Suspension type
Rear shock absorber assembly
type
Rear shock absorber assembly
travel
Spring
Free length
Installed length
Spring rate (K1)
Spring stroke (K1)
Optional spring available
Standard spring preload gas/air
pressure
Spring preload adjusting positions
Minimum
Standard
Maximum
Rebound damping adjusting
positions
Minimum*
Standard*
Maximum*
Compression damping adjusting
positions
Minimum*
Standard*
Maximum*
*with the adjusting screw fully turned
in position
SPEC
Standard
Limit
Swingarm (link suspension)
Coil spring/gas-oil damper
65 mm
176 mm
162.5 mm
78.4 N/mm (7.84 kgf/mm)
0 65 mm
No
1,200 kPa (12 kgf/cm2)
1
4
9
11
7
1
11
9
1
–8–
ELECTRICAL SPECIFICATIONS
SPEC
ELECTRICAL SPECIFICATIONS
Item
Standard
Limit
System voltage
12 V
SSS
Ignition system
Ignition system type
Ignition timing
Advanced timing
Advancer type
Pickup coil resistance/color
Transistorized coil ignition unit
model (manufacturer)
Transistorized coil ignition
5_ BTDC at 1,050 r/min
55_ BTDC at 5,000 r/min
Throttle position sensor and electrical
248 372 W/Gy-B
TNDF54 (DENSO)
SSS
SSS
SSS
SSS
SSS
SSS
Voltage regulator
Regulator type
Model
No-load regulated voltage
Semiconductor short circuit
SH650A-12
14.1 14.9 V
SSS
SSS
SSS
Bulbs (voltage/wattage quantity)
Headlight
Auxiliary light
Tail/brake light
Turn signal light
Meter light
12 V 60 W/55 W 2
12 V 5 W 2
12 V 5 W/21 W 2
12 V 21 W 4
LED
SSS
SSS
SSS
SSS
SSS
Constant mesh
SSS
5JJ (YAMAHA)
0.75 kW
SSS
SSS
9.8 mm
4.88 7.32 N (488 732 gf)
0.009 0.011 Ω
24.5 mm
1.5 mm
3.65 mm
SSS
SSS
23.5 mm
SSS
Full-transistor
FE246BH (DENSO)
No
75 95 cycles/min.
21 W 2
SSS
SSS
SSS
SSS
SSS
Oil level switch model
(manufacturer)
4XV (DENSO)
SSS
Fuel pump relay model
(manufacturer)
G8R-30Y-M (OMRON)
SSS
Electric starting system
System type
Starter motor
Model (manufacturer)
Power output
Brushes
Overall length
Spring force
Commutator resistance
Commutator diameter
Mica undercut
Turn signal relay
Relay type
Model (manufacturer)
Self-cancelling device built-in
Turn signal blinking frequency
Wattage
–9–
ELECTRICAL SPECIFICATIONS
Item
Thermo unit
Model (manufacturer)
Fuses (amperage quantity)
Main fuse
Headlight fuse
Signaling system fuse
Ignition fuse
Radiator fan fuse
Backup fuse (odometer)
Reserve fuse
SPEC
Standard
Limit
5JJ (NIPPON THERMOSTAT)
30 A 1
20 A 1
20 A 1
15 A 1
10 A 1
10 A 1
30 A 1
20 A 1
15 A 1
10 A 1
–10–
TIGHTENING TORQUES
SPEC
TIGHTENING TORQUES
ENGINE TIGHTENING TORQUES
Item
Cylinder head
Cylinder head
Generator rotor
Oil/water pump assembly driven
sprocket cover
Air induction system hose
Crankcase
Crankcase
Crankcase
Crankcase
Ignitor unit
Thread
size
Q’ty
y
Nut
Cap nut
Bolt
Bolt
M10
M10
M10
M6
Clamp
Bolt
Bolt
Bolt
Bolt
Screw
M7
M9
M6
M6
M8
M5
Fastener
NOTE:
After tightening to 15 Nm (1.5 mSkg), tighten another 45_ 50_
–11–
Tightening
torque
Nm
mSkgf
8
2
1
1
50
65
65
12
5.0
6.5
6.5
1.2
4
10
2
14
2
2
4
0.4
See NOTE
14
1.4
12
1.2
24
2.4
7
0.7
Remarks
TIGHTENING TORQUES
SPEC
CHASSIS TIGHTENING TORQUES
Item
Thread size
Lower ring nut
Engine mounting
Front mounting bolts
Rear upper mounting bolt
Rear under mounting bolts
Pinch bolts
Exhaust pipe bracket
Rear master cylinder
Tightening
Nm
mkgf
M30
9
0.9
M10
M10
M10
M8
M8
M8
40
55
55
24
24
18
4.0
5.5
5.5
2.4
2.4
1.8
Remarks
See NOTE.
NOTE:
1. First, tighten the ring nut to approximately 18 Nm (1.8 mkg) with a torque wrench, then loosen the
ring nut completely.
2. Retighten the ring nut to specification.
–12–
LUBRICATION POINTS AND LUBRICANT TYPES
SPEC
E202000
LUBRICATION POINTS AND LUBRICANT TYPES
ENGINE LUBRICATION POINTS AND LUBRICANT TYPES
Lubricant
Lubrication point
Connecting rod bolts and nuts
–13–
OIL FLOW DIAGRAMS
EB203000
OIL FLOW DIAGRAMS
1
2
3
4
5
6
7
Intake camshaft
Exhaust camshaft
Crankshaft
Oil cooler
Oil pipe
Oil strainer
Oil pump
–14–
SPEC
OIL FLOW DIAGRAMS
1 Exhaust camshaft
2 Intake camshaft
3 Oil filter
–15–
SPEC
OIL FLOW DIAGRAMS
1 Cylinder head
2 Crankshaft
–16–
SPEC
COOLANT FLOW DIAGRAMS
EB203000
COOLANT FLOW DIAGRAMS
1
2
3
4
5
6
Thermostat
Radiator cap
Coolant reservoir
Radiator
Oil cooler
Water jacket joint
–17–
SPEC
COOLANT FLOW DIAGRAMS
1
2
3
4
Thermostat housing
Water pump
Radiator
Radiator fan
–18–
SPEC
COOLANT FLOW DIAGRAMS
1 Radiator
2 Thermo unit
–19–
SPEC
CABLE ROUTING
SPEC
EB206000
CABLE ROUTING
1
2
3
4
5
Clutch cable
Left handlebar switch lead
Starter cable
Main switch lead
Steering cover
A Properly insert the meter assembly coupler and rubber boot into the
meter assembly.
B Route the meter assembly lead through the left side of the headlight
housing.
C The speedometer lead with not be tighten.
D Install the headlight relays onto the headlight housing bridge.
E Connect to the right front turn signal connectors.
F Route the turn signal leads upper the headlight housing boss.
–20–
CABLE ROUTING
G Fasten the headlight lead with a plastic clamp at
white tape mark.
H Fasten the wire harness to the headlight housing
boss with a plastic locking tie.
I Route the headlight lead through the plastic guide.
J Route the throttle cable to the front side of the brake
hose.
K Route the clutch cable behind the front fork leg.
L Make sure that the horn leads face out.
M Route the throttle cables and right handlebar
switch lead between the lower bracket and steering
cover.
SPEC
N Route the thermo switch / temperature sender subwire harness to the outside of the radiator cap.
O Route the right handlebar switch lead behind the
throttle cables. Do not cross the throttle cables and
the right handlebar switch lead.
P Route the right handlebar switch lead in front of the
throttle cables.
–21–
CABLE ROUTING
Rollover valve (California only)
Charcoal canister (California only)
Rear brake switch lead
Timing chain tensioner.
Thermostat assembly breather hose
Radiator inlet hose
Coolant reservoir breather hose
Clutch cable
Pickup coil lead
A Fasten the starter motor lead to the flame which is
just before the side cover stay (0 5 mm) with a
plastic clamp.
B 0 5 mm
1
2
3
4
5
6
7
8
9
SPEC
C Route the rollover-valve-to-fuel-tank hose to the inside of the fuel hose (California only).
D Route the coolant reservoir breather hose over the
timing chain tensioner.
E Insert the plastic clip through the hole in the plastic
frame panel and then fasten the wire harness and
coolant reservoir breather hose with it.
F Route the clutch cable between the radiator bracket and frame and in front of the thermostat assembly breather hose.
G Route the clutch cable to the inside of the radiator
inlet hose.
H Insert the plastic clamp into the hole in the coolant
reservoir’s tab.
–22–
CABLE ROUTING
1 Starter cable
2 Air induction system vacuum
3
4
5
6
7
8
9
10
11
hose
Air induction system hose
Sidestand switch lead
Oil level switch lead
Clamp
Right handlebar switch lead
Throttle cables
Air guide
Air filter case breather hose
Coolant reservoir breather hose
SPEC
Fuel tank overflow hose and fuel tank breather hose
Drive chain sprocket cover
Coolant hose
EXUP servomotor
A Route the air filter case breather hose and air induction system hose
to the inside of the wire harness.
B Through the air cleaner drain hose, coolant reservoir tank breather,
fuel tank breather hose, fuel tank over flow hose, air induction system
hose and air induction system vacuum hose outside of the AC magneto lead. Then, clamp all of them at just behind of the air induction
system protector and air induction system vacuum hose protector,
moreover at under the three sides pipe.
12
13
14
15
–23–
CABLE ROUTING
C
D
E
F
SPEC
To the connector cover.
J Route the sidestand switch lead and oil level switch
Route the seat lock cable over the wire harness.
lead to the inside of the drive sprocket cover.
Fasten the wire harness with a plastic clamp.
K Do not crush the water pump breather hose and
Make sure the rear flasher light lead coupler and
plastic clip.
tail light lead coupler in the rubber cover.
L Pass the fuel tank breather hose and the air filter
G Route the rear turn signal lead through the hole in the
drain hose through the steel clamps and then after
upper rear fender.
routing the hoses to the exterior of the under cowlH 50 mm
ing, align the leading ends of the hoses.
I Fasten the sidestand switch lead, engine oil level M Route the engine oil level switch lead and sideswitch lead, and water pump breather hose with a
stand switch lead inside the coolant hose.
plastic clip.
–24–
CABLE ROUTING
N Pass the fuel tank breather hose and the air filter Q
drain hose through the inside of the coolant hose. R
No hose must be inserted into the under cowling. S
O Pass the air filter drain hose and the coolant reservoir hose through the inside of the coolant hose
and route the leading ends to the bottom of the T
coolant hose. The leading ends must not protrude
from the under cowling.
U
P Fasten the air filter drain hose, coolant hose, cool- V
ant reservoir tank breather hose, fuel tank breather
hose, fuel tank drain hose and air induction system W
hose at the steel clamp.
SPEC
To the air filter.
To the fuel tank.
Insert the fuel tank breather hose into a back side
nipple of fuel tank. The fuel tank nipple and the fuel
tank breather hose have each white mark.
Insert the fuel tank over flow hose into a front side
nipple of fuel tank.
To the air vent surge tank.
Adjust the all clip’s direction to back side of the
body.
Clamp under a three sides pipe.
–25–
CABLE ROUTING
Speed sensor lead
Charcoal canister (California only)
EXUP cables
EXUP
A Route the EXUP cables behind the cross tube.
B Route the neutral switch lead direct to upper right
side.
C Route the EXUP cables on the outside of the engine mount.
1
2
3
4
SPEC
D Route the EXUP cables behind the swing arm head
pipe.
E Fasten the EXUP cables and engine mount with a
plastic locking tie.
–26–
CABLE ROUTING
1
2
3
4
5
6
7
8
9
10
11
12
Headlight sub-wire harness
Left handlebar switch lead
Main switch lead
Starter cable
Right handlebar switch coupler
Throttle cables
Engine air vent hose
EXUP servomotor coupler
Air vent surge tank
Starter motor lead
Pickup coil coupler
Fuel pump coupler
13
14
15
16
17
18
19
20
21
22
23
24
SPEC
Neutral switch connector
Battery negative lead
Rear brake switch coupler
Speed sensor coupler
EXUP cable
Fuel tank overflow hose
Fuel tank breather hose (except for California)
Tail light lead
Rear flasher light lead
Crankcase breather hose
Generator coupler
Sidestand switch coupler
–27–
CABLE ROUTING
25
26
27
28
29
30
31
32
33
34
35
Engine oil level switch lead
Air filter case drain hose
Air induction system hose
Ignition coil
Cover
Rivet
Screw
Coupler
Main harness
Frame
Rear fender
–28–
SPEC
CABLE ROUTING
A Make sure the headlight lead in the rubber cover.
B Route the horn lead over the horn bracket and
make sure that the lead has no slack.
C Do not cross the throttle cables and right handlebar
switch lead.
D Route the thermo switch lead through the steel
band on the radiator.
E Fasten the main harness and thermo switch lead
with a plastic clamp. Insert the plastic clamp into
the hole on the frame.
F Route the ignition coil sub-wire harness under the
throttle position sensor.
SPEC
G To the carburetor.
H Route the coolant reservoir tank breather hose upper the air vent surge tank.
I Fasten the wire harness and ignition coil subwire
harness with a plastic clamp.
J Route the idle adjust cable upper the ground lead.
K Fasten the fuel pump lead, speed sensor lead,
neutral switch lead, rear brake light lead, fuel sender lead, starter motor lead and EXUP cable with a
plastic clamp.
–29–
CABLE ROUTING
SPEC
L Fasten the fuel pump lead, speed sensor lead,
tank breather hose have each white mark.
neutral switch lead, rear brake light lead, fuel send- S 30 mm (1.17 in)
er lead, starter motor lead and EXUP cable with a T Fasten the battery positive lead and starter motor
plastic clamp.
lead with a plastic locking tie.
M 125 mm (4.88 in)
U Route the rear flasher light lead in the hole on the
N 50 mm (1.95 in)
rear fender.
O To the fuel cock.
V Insert the tail / brake light lead and turn signal leads
P To the fuel sender.
under the tail / brake light.
Q Insert the fuel tank over flow hose into a front side W Fasten the rear flasher light lead and taillight lead
nipple of fuel tank.
with a plastic clamp. Route the rear flasher light
R Insert the fuel tank breather hose into a back side
lead and taillight lead in the hole on the taillight
nipple of fuel tank. The fuel tank nipple and the fuel
bracket.
–30–
CABLE ROUTING
X Fasten the main harness with a plastic band on the
rear fender.
Y Position the ground coupler over the main harness.
Z Route the ground lead under the starter relay lead.
A’ Fasten the starter relay lead, ground lead, starting
circuit cutoff relay lead, alam lead and main harness
with a plastic clamp. Route the clamp end to outside,
and insert it between wire harness and fender.
B’ Route the taillight leads through the rear fender.
C’ Fasten the main harness, battery negative lead
and rear fender with a plastic clamp. Clamp the battery negative lead with a white tape mark.
SPEC
D’ At the back side of turning point, battery negative
lead is fixed to wire harness.
E’ Route the fuel tank overflow hose and fuel tank
breather hose in front of the crank case breather
hose and under the fuel hose and front of the EXUP
servomotor bracket and upper the EXUP servomotor.
F’ To the idle adjust screw.
G’ To the engine backward.
H’ Make sure the sidestand switch coupler, engine oil
level sensor coupler, EXUP servo motor coupler
and acmagneto coupler in the rubber cover.
–31–
CABLE ROUTING
I’ Fasten the main harness with a plastic clamp. Insert the plastic clamp into the hole on the frame.
J’ Route the charcoal canister hose under the engine
air vent hose, coolant reservoir tank breather hose
and all of leads. (California only)
K’ Fasten the wire harness with a plastic clamp and
then insert the clamp into the frame.
L’ To the radiator fan motor.
M’ Route the main harness and fan motor lead into the
hole on the air intake guide. Fasten the main harness and fan motor lead with a plastic clamp.
N’ Route the band end to inside. The clamp position
SPEC
should be not exceed just behind 30 mm of all coupler.
O’ 0 30 mm
P’ Although the main switch lead couplers and the handlebar switch lead couplers are the same in shape,
they differ in color (the former is white, and the latter,
blue). Connect the couplers of the same color.
Q’ Direct the ignition coil leads upward and insert
them into position at the rubber damper.
R’ 90_
S’ Route the battery negative lead inside the main
harness.
T’ Route the battery positive lead upper the main harness.
–32–
PERIODIC MAINTENANCE AND
LUBRICATION INTERVALS
CHK
ADJ
EB300000
PERIODIC CHECKS AND ADJUSTMENTS
INTRODUCTION
This chapter includes all information necessary to perform recommended checks and adjustments. If
followed, these preventive maintenance procedures will ensure more reliable vehicle operation, a
longer service life and reduce the need for costly overhaul work. This information applies to vehicles
already in service as well as to new vehicles that are being prepared for sale. All service technicians
should be familiar with this entire chapter.
EB301000
PERIODIC MAINTENANCE AND LUBRICATION INTERVALS
No
No.
ITEM
CHECKS AND MAINTENANCE JOBS
1
* Fuel line
Check fuel hoses and vacuum hose for cracks or
damage.
Replace if necessary.
2
* Fuel filter
Check condition.
Replace if necessary.
3
4
Spark plugs
* Valves
After the
first
1,000 km
Every
Every
10,000 km
20,000 km
Annual
check
Check condition.
Clean, regap or replace if necessary.
Check valve clearance.
Adjust if necessary.
Every 40,000 km
5
Air filter
Clean or replace if necessary.
6
Clutch
Check operation.
Adjust or replace cable.
7
* Front brake
Check operation, fluid level and vehicle for fluid leakage.
Correct accordingly.
Replace brake pads if necessary.
8
* Rear brake
Check operation, fluid level and vehicle for fluid leakage.
Correct accordingly.
Replace brake pads if necessary.
9
* Brake hose
Check for cracks or damage.
Replace if necessary.
10 * Wheels
Check balance, runout and for damage.
Rebalance or replace if necessary.
11 * Tires
Check tread depth and for damage.
Replace if necessary.
Check air pressure.
Correct if necessary.
Check bearing for looseness or damage.
Replace if necessary.
13 * Swingarm
Check swingarm pivoting point for play.
Correct if necessary.
Lubricate with lithium soap base grease.
14
Drive chain
Check chain slack.
Adjust if necessary. Make sure that the rear wheel is
properly aligned.
Clean and lubricate.
Every 1,000 km and after washing the
motorcycle or riding in the rain
15 *
Steering
bearings
Check bearing play and Steering for roughness.
Correct accordingly.
12 *
Wheel
bearings
Lubricate with lithium soap base grease.
–33–
Every 24,000 km
PERIODIC MAINTENANCE AND
LUBRICATION INTERVALS
No
No.
ITEM
CHECKS AND MAINTENANCE JOBS
After the
first
1,000 km
CHK
ADJ
Every
Every
10,000 km
20,000 km
Annual
check
16 *
Chassis
fasteners
S Make sure that all nuts, bolts and screws are properly
tightened.
S Tighten if necessary.
17
Sidestand
S Check operation.
S Lubricate and repair if necessary.
18 *
Sidestand
switch
S Check operation.
S Replace if necessary.
19 * Front fork
S Check operation and for oil leakage.
S Correct accordingly.
Rear shock
20 * absorber
assembly
S Check operation and shock absorber for oil leakage.
S Replace shock absorber assembly if necessary.
Rear
suspension
21 * relay arm and
connecting arm
pivoting points
S Check operation.
S Correct if necessary.
22 * Carburetors
S Check engine idling speed, synchronization and
starter operation.
S Adjust if necessary.
23
Engine oil
S Check oil level and vehicle for oil leakage.
S Correct if necessary.
S Change. (Warm engine before draining.)
24
Engine oil
filter cartridge
S Replace.
25 *
Cooling
system
Cooling
system
S Check coolant level and vehicle for coolant leakage.
S Correct if necessary.
Front and rear
26 * brake
switches
S Change coolant.
S Check operation.
S Correct accordingly.
27
Moving parts
and cables
S Lubricate if necessary.
28 *
Air induction
system
S Check the air cut valve and reed valve for damage.
S Replace the entire air induction system if necessary.
29 *
Exhaust
system
S Check the screw clamp for looseness.
S Tighten if necessary.
30 *
Lights, signals
and switches
S Check operation.
S Correct if necessary.
S Adjust headlight beam if necessary.
* Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service.
NOTE:
D The annual checks must be performed once a year unless a 10,000 km or 20,000 km maintenance
was performed in the same year.
D The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
D Hydraulic brake service
S Regularly check and, if necessary, correct the brake fluid level.
S Every two years replace the internal components of the brake master cylinder and caliper, and
change the brake fluid.
S Replace the brake hoses every four years and if cracked or damaged.
–34–
COWLINGS
CHK
ADJ
EB302020
COWLINGS
5 Nm (0.5 mkg)
Order
1
2
3
4
5
6
7
8
9
Job/Part
Removing the cowlings
Rider and passenger seats
Rear cowling
Bottom cowling
Front cowling inner panel (left)
Front cowling inner panel (right)
Left side cowling
Right side cowling
Windshield
Rear view mirror
Front cowling
Q’ty
Remarks
Remove the parts in the order listed.
Refer to “SEATS”.
1
1
1
1
1
1
1
2
1
Front installation, reverse the removal
procedure.
–35–
AIR FILTER CASE AND IGNITION COIL PLATE
CHK
ADJ
EB302040
AIR FILTER CASE AND IGNITION COIL PLATE
Order
1
2
3
4
5
6
7
8
9
10
11
Job/Part
Removing the air filter case and
ignition coil plate
Rider seat and fuel tank
Crankcase breather hose
Air filter case breather hose
Air induction system hose
Clamp screw
Bolt
Air filter case
Quick fastener
Ignition coil coupler
Spark plug cap
Ignition coil plate/ignition coil
Rubber baffle
Q’ty
Remarks
Remove the parts in the order listed.
Refer to “SEATS” and “FUEL TANK”.
1
1
1
4
1
1
2
1
4
1/2
1
Loosen.
Disconnect.
For installation, reverse the removal
procedure.
–36–
ENGINE
CHK
ADJ
OVERHAULING THE ENGINE
AIR INDUCTION SYSTEM
4 Nm (0.4 mkg)
Order
1
2
3
4
Job/Part
Q’ty
Removing the air induction system
Air induction pipe
Air cutoff valve
Carburetor joint hose
Air intake hose
Remarks
Remove the parts in the order listed.
4
1
1
1
For installation, reverse the removal
procedure.
–37–
ENGINE
ENG
ENGINE
24 Nm (2.4 mkg)
40 Nm (4.4 mkg)
55 Nm (5.5 mkg)
40 Nm (4.0 mkg)
55 Nm (5.5 mkg)
Order
24 Nm (2.4 mkg)
Job/Part
Q’ty
Remove the parts in the order listed.
NOTE:
Place a suitable stand under the frame and
engine.
Removing the engine
1
2
3
4
5
6
7
8
9
Pinch bolt
Right front mounting bolt
Washer
Spacer
Left front mounting bolt
Washer
Self-locking nut
Rear mounting bolt
Spacer
Remarks
2
1
1
1
2
2
2
2
1
Loosen.
For installation, reverse the removal
procedure.
–38–
ENGINE
ENG
EB400700
INSTALLING THE ENGINE
1. Install:
engine assembly
a. Install the spacer 1 to the frame.
b. Temporally tighten the right front mounting
bolt 2 , left front mounting bolt 3 , and washers 4 5 .
c. Lubricate the rear mounting bolts 6 7
threads with lithium soap base grease.
d. Install the rear mounting bolts 6 7 and self
locking nut 8 9 .
e. Tighten the self locking nut 8 , and then tighten the self locking nut 9 .
f. Tighten the pinch bolt 10 .
g. Tighten the left mounting bolt 3 .
h. Tighten the right mouthing bolt 2 .
i. Tighten the pinch bolt 11 .
Self locking nut 8 9
55 Nm (5.5 mkg)
Right front mounting bolt 2
40 Nm (4.0 mkg)
Left front mounting bolt 3
40 Nm (4.0 mkg)
Pinch bolts 10 11
24 Nm (2.4 mkg)
–39–
CYLINDER HEAD
ENG
EB402000
CYLINDER HEAD
50 Nm (5.0 mkg)
65 Nm (6.5 mkg)
12 Nm (1.2 mkg)
Order
1
2
3
Job/Part
Removing the cylinder head
Engine
Intake and exhaust camshafts
Cylinder head
Cylinder head gasket
Dowel pin
Q’ty
Remarks
Remove the parts in the order listed.
Refer to “ENGINE”.
Refer to “CAMSHAFTS”.
1
1
2
For installation, reverse the removal
procedure.
–40–
CRANKCASE
ENG
CRANKCASE
10 Nm (1.0 mkg)
10 Nm (1.0 mkg)
Order
1
2
3
4
5
Job/Part
Q’ty
Separating the crankcase
Engine
Cylinder head
Pickup coil and pickup coil rotor
Stator coil assembly
Clutch housing and starter clutch
idle gear
Oil/water pump assembly
Timing chain
Crankshaft sprocket
Pin
Oil/water pump assembly drive chain
guide
Oil/water pump assembly drive chain
Remarks
Remove the parts in the order listed.
Refer to “ENGINE”.
Refer to “CYLINDER HEAD”.
Refer to “PICKUP COIL”.
Refer to “GENERATOR”.
Refer to “CLUTCH”.
Refer to “OIL PAN AND OIL PUMP”.
1
1
1
1
1
–41–
CRANKCASE
ENG
10 Nm (1.0 mkg)
10 Nm (1.0 mkg)
Order
6
7
8
9
10
Job/Part
Oil/water pump assembly drive
sprocket
Washer
Plate
Lower crankcase
Dowel pin
Q’ty
Remarks
1
1
1
1
3
For installation, reverse the removal
procedure.
–42–
CRANKCASE
ENG
EB412743
ASSEMBLING THE CRANKCASE
1. Lubricate:
crankshaft journal bearings
(with the recommended lubricant)
Recommended lubricant
Engine oil
2. Apply:
sealant
(onto the crankcase mating surfaces and the
groove a of the oil baffle plate)
Yamaha bond No. 1215
90890-85505
NOTE:
Do not allow any sealant to come into contact
with the oil gallery or crankshaft journal bearings. Do not apply sealant to within 2 X 3 mm of
the crankshaft journal bearings.
3. Install:
dowel pin
4. Install:
crankshaft journal lower bearings
(into the lower crankcase)
NOTE:
Align the projections a on the crankshaft journal lower bearings with the notches b in the
lower crankcase.
Install each crankshaft journal lower bearing in
its original place.
5. Set the shift drum assembly and transmission gears in the neutral position.
–43–
CRANKCASE
ENG
6. Install:
S lower crankcase 1
(onto the upper crankcase 2 )
CAUTION:
Before tightening the crankcase bolts, make
sure that the transmission gears shift correctly when the shift drum assembly is
turned by hand.
7. Install:
S crankcase bolts
NOTE:
S Lubricate the bolt threads with engine oil.
S Install a washer on bolts 1 X 10 .
S Tighten each bolt at 15 Nm in the tightening sequence cast on the crankcase.
S Loosen each bolt one time and tighten 15 Nm
in the same sequence.
S Tighten bolts 1 to 10 45_ X 50_ more.
S Tighten bolts 11 to 28 as shown below.
M9
M8
M8
M6
M6
M6
M6
M6
M6
M6
115 mm bolts: 1 X 10
60 mm bolt: 21
50 mm bolt: 22
70 mm bolts: 17 , 19 , 25
65 mm bolt: 27
64 mm bolts: 16 , 24
60 mm bolt: 23
55 mm bolts: 11 X 15
50 mm bolt: 18
45 mm bolts: 20 , 26 , 28
Bolt 1 X 10
15 Nm (1.5 mSkg) + 45_ X 50_
Bolt 11 X 15 , 17 X 20 , 23 , 25 X 28
12 Nm (1.2 mSkg)
Bolt 16 , 24
14 Nm (1.4 mSkg)
Bolt 21 , 22
24 Nm (2.4 mSkg)
–44–
RADIATOR
COOL
EB500000
COOLING SYSTEM
RADIATOR
10 Nm (1.0 mkg)
20 Nm (2.0 mkg)
9 Nm (0.9 mkg)
23 Nm (2.3 mkg)
4.5 Nm (0.45 mkg)
Order
Job/Part
Q’ty
Remove the parts in the order listed.
Refer to “SEATS” and “FUEL TANK” in
chapter 3.
Refer to “AIR FILTER CASE AND IGNITION COIL PLATE” in chapter 3.
Refer to “COWLINGS” in chapter 3.
Refer to “ENGINE” in chapter 4.
Drain.
Refer to “CHANGING THE COOLANT” in
chapter 3.
Removing the radiator
Rider seat and fuel tank
Air filter case and rubber cover
Bottom cowling and side cowlings
Drive sprocket cover
Coolant
1
2
3
4
Coolant reservoir breather hose
Coolant reservoir hose
Coolant reservoir
Thermo unit coupler
Remarks
1
1
1
1
–45–
Disconnect.
RADIATOR
COOL
10 Nm (1.0 mkg)
20 Nm (2.0 mkg)
9 Nm (0.9 mkg)
23 Nm (2.3 mkg)
4.5 Nm (0.45 mkg)
Order
5
6
7
8
9
10
11
12
13
14
15
Job/Part
Thermo unit
Thermostat assembly breather hose
Radiator inlet hose
Oil cooler outlet hose
Water pump breather hose
Radiator outlet hose
Water pump inlet pipe
Radiator fan motor coupler
Horn bracket
Radiator
Radiator fan
Q’ty
1
1
1
1
1
1
1
1
1
1
1
Remarks
Disconnect.
Disconnect.
Disconnect.
For installation, reverse the removal
procedure.
–46–
AIR INDUCTION SYSTEM
CARB
EAS00507
CARBURETORS
AIR INDUCTION SYSTEM
AIR INJECTION
The air induction system burns unburned exhaust gases by injecting fresh air (secondary
air) into the exhaust port, reducing the emission
of hydrocarbons.
When there is negative pressure at the exhaust
port, the reed valve opens, allowing secondary
air to flow into the exhaust port. The required
temperature for burning the unburned exhaust
gases is approximately 600 to 700_C.
EAS00508
AIR CUTOFF VALVE
The air cutoff valve is operated by the intake gas
pressure through the piston valve diaphragm.
Normally, the air cutoff valve is open to allow
fresh air to flow into the exhaust port. During
sudden deceleration (the throttle valve suddenly closes), negative pressure is generated and
the air cutoff valve is closed in order to prevent
after-burning.
Additionally, at high engine speeds and when
the pressure decreases, the air cutoff valve automatically closes to guard against a loss of performance due to self-EGR.
(This “low-boost close” function is the same as
on the FZR600 (3HW).)
VIEW 1. (NO FLOW)
VIEW 1. (NO FLOW)
When decelerating (the throttle closes), the
valve will close.
VIEW 2. (FLOW)
During normal operation the valve is open.
A From the air filter
B To the reed valve
C To the carburetor joint
VIEW 2. (FLOW)
–47–
AIR INDUCTION SYSTEM
EAS00509
AIR INDUCTION SYSTEM DIAGRAMS
1
2
3
4
Reed valve
Air cleaner
Air cutoff valve
Carburetor joint (cylinder #1)
A
B
D
D
E
–48–
To the air cutoff valve
To cylinder #1
To cylinder #2
To cylinder #3
To cylinder #4
CARB
AIR INDUCTION SYSTEM
CARB
EAS00510
CHECKING THE AIR INDUCTION SYSTEM
1. Check:
hoses
Loose connection Connect properly.
Cracks/damage Replace.
pipes
Cracks/damage Replace.
2. Check:
fibre reed 1
fibre reed stopper
reed valve seat
Cracks/damage Replace.
3. Measure:
fibre reed bending limit a
Out of specification Replace the reed
valve.
Fibre reed bending limit
0.4 mm
1 Surface plate
4. Check:
air cutoff valve
Cracks/damage Replace.
–49–
FRONT WHEEL AND BRAKE DISCS
CHAS
EB700002
CHASSIS
FRONT WHEEL AND BRAKE DISCS
6 Nm (0.6 mkg)
72 Nm (7.2 mkg)
40 Nm (4.0 mkg)
18 Nm (1.8 mkg)
Order
Job/Part
Q’ty
Remove the parts in the order listed.
NOTE:
Place the motorcycle on a suitable stand
so that the front wheel is elevated.
Removing the front wheel and brake
discs
1
2
3
4
5
6
7
8
Brake hose holder (left and right)
Brake caliper (left and right)
Wheel axle pinch bolt
Front wheel axle
Front wheel
Collar (left and right)
Oil seal cover (left and right)
Brake disc (left and right)
Remarks
2
2
1
1
1
2
2
2
Loosen.
Refer to “INSTALLING THE FRONT
WHEEL”.
For installation, reverse the removal
procedure.
–50–
FRONT WHEEL AND BRAKE DISCS
CHAS
EB700725
INSTALLING THE FRONT WHEEL
1. Lubricate:
wheel axle
oil seal lips
Recommended lubricant
Lithium soap base grease
2. Install:
brake discs 1
18 Nm (1.8 mkg)
NOTE:
Apply LOCTITE 648 to the threads of the
brake disc bolts.
Tighten the brake disc bolts in stages and in a
crisscross pattern.
3. Tighten:
wheel axle 1
wheel axle pinch bolt 1
72 Nm (7.2 mkg)
23 Nm (2.3 mkg)
NOTE:
When front wheel is installed to front fork, make
sure that wheel axle 1 top end side and front
fork end side are align a together. Then, tighten wheel axle pinch bolt 2 .
CAUTION:
Before tightening the wheel axle nut, push
down hard on the handlebars several times
and check if the front fork rebounds smoothly.
4. Install:
brake calipers
40 Nm (4.0 mkg)
WARNING
Make sure that the brake hose is routed
properly.
–51–
FRONT AND REAR BRAKES
CHAS
EB702202
FRONT AND REAR BRAKES
REAR BRAKE MASTER CYLINDER AND BRAKE FLUID RESERVOIR
5 Nm (0.5 mkg)
30 Nm (3.0 mkg)
23 Nm (2.3 mkg)
Order
Job/Part
Q’ty
1
2
3
4
5
6
7
8
9
10
Removing the rear brake master
cylinder and brake fluid reservoir
Brake fluid
Brake fluid reservoir cap
Brake fluid reservoir diaphragm holder
Brake fluid reservoir diaphragm
Brake fluid reservoir
Brake fluid reservoir hose
Hose joint
Union bolt
Copper washer
Brake hose
Brake master cylinder
Remarks
Remove the parts in the order listed.
Drain.
1
1
1
1
1
1
1
2
1
1
For installation, reverse the removal
procedure.
–52–
INSTRUMENT FUNCTIONS
ELEC
ELECTRICAL
INSTRUMENT FUNCTIONS
INDICATOR LIGHTS
Neutral indicator light “ ”
This indicator light comes on when the transmission is in the neutral position.
”
High beam indicator light “
This indicator comes on when the headlight
high beam is used.
Turn signal indicator light “
”
This indicator light flashes when the turn signal
switch is pushed to the left or right.
1
2
3
4
5
Neutral indicator light “
”
High beam indicator light “
”
Turn signal indicator light “
”
Fuel level warning light “
”
Oil level warning light “
”
Fuel level warning light “ ”
This warning light comes on when the fuel level
drops below approximately 3.8 L. When this occurs, refuel as soon as possible.
The electrical circuit of the warning light can be
checked according to the following procedure.
1. Set the engine stop switch to “ ” and turn
the key to “ON”.
2. Shift the transmission into the neutral position or pull the clutch lever.
3. Push the start switch. If the warning light
does not come on while pushing the start
switch, have a Yamaha dealer check the
electrical circuit.
NOTE:
This model is equipped with a selfdiagnosis device for the fuel level warning light circuit. Refer
to “SELF-DIAGNOSIS”.
Oil level warning light “
”
This warning light comes on when the engine oil
level is low.
The electrical circuit of the warning light can be
checked according to the following procedure.
1. Set the engine stop switch to “ ” and turn
the key to “ON”.
2. Shift the transmission into the neutral position or pull the clutch lever.
3. Push the start switch. If the warning light
does not come on while pushing the start
switch, have a Yamaha dealer check the
electrical circuit.
NOTE:
Even if the oil level is sufficient, the warning light
may flicker when riding on a slope or during sudden acceleration or deceleration, but this is not
a malfunction.
–53–
INSTRUMENT FUNCTIONS
ELEC
COOLANT TEMPERATURE WARNING LIGHT
1 Coolant temperature gauge
2 Coolant temperature warning light “
Coolant temperature warning light “ ”
This warning light comes on when the engine
overheats. When this occurs, stop the engine
immediately and allow the engine to cool.
The electrical circuit of the warning light can be
checked according to the following procedure.
1. Set the engine stop switch to “ ” and turn
the key to “ON”.
2. Shift the transmission into the neutral position or pull the clutch lever.
3. Push the start switch. If the warning light
does not come on while pushing the start
switch, have a Yamaha dealer check the
electrical circuit.
”
CAUTION:
Do not operate the engine if it is overheated.
Coolant
temperature
Display
Conditions
What to do
Message “LO” is
displayed.
OK. Go ahead with
riding.
Temperature is
displayed.
OK. Go ahead with
riding.
117 – 139_C
Temperature
flashes.
Warning light
comes on.
Stop the motorcycle and
allow it to idle until the
coolant temperature
goes down.
If the temperature does
not go down, stop the
engine. Refer to “OVER
HEATING” in chapter 9.
Above 140_C
Message “HI”
flashes.
Warning light
comes on.
Stop the engine and
allow it to cool.
Refer to “OVER
HEATING” in chapter 9.
0 – 39_C
40 – 116_C
–54–
INSTRUMENT FUNCTIONS
ELEC
SPEEDOMETER UNIT
The speedometer unit is equipped with the following:
a digital speedometer (which shows riding
speed)
an odometer (which shows the total distance
traveled)
two tripmeters (which show the distance
traveled since they were last set to zero)
a fuel reserve tripmeter (which shows the distance traveled on the fuel reserve)
a clock
1 Speedometer
2 Odometer / tripmeter / fuel reserve tripmeter /
clock
3 “RESET” button
4 “SELECT” button
Odometer and tripmeter modes
Pushing the “SELECT” button switches the display between the odometer mode “ODO” and
the tripmeter modes “TRIP 1” and “TRIP 2” in
the following order:
ODO TRIP 1 TRIP 2 ODO
If the fuel level warning light comes on (see
page 3-2), the odometer display will automatically change to the fuel reserve tripmeter mode
“TRIP F” and start counting the distance traveled from that point. In that case, pushing the
“SELECT” button switches the display between
the various tripmeter and odometer modes in
the following order:
TRIP F TRIP 1 TRIP 2 ODO TRIP F
To reset a tripmeter, select it by pushing the “SELECT” button, and then push the “RESET” button. If you do not reset the fuel reserve tripmeter
manually, it will reset itself automatically and the
display will return to “TRIP 1” after refueling and
traveling 5 km.
NOTE:
After resetting the fuel reserve tripmeter, the
display will return to “TRIP 1”, unless a different
mode had been previously selected; in that
case, the display automatically returns to the
prior mode.
–55–
INSTRUMENT FUNCTIONS
ELEC
Clock mode
To change the display to the clock mode, push
the “SELECT” button for at least one second.
To change the display back to the odometer
modes, push the “SELECT” button.
To set the clock:
1. Push the “SELECT” button and “RESET”
button together for at least two seconds.
2. When the hour digits start flashing, push the
“RESET” button to set the hours.
3. Push the “SELECT” button, and the minute
digits will start flashing.
4. Push the “RESET” button to set the minutes.
5. Push the “SELECT” button and then release
it to start the clock.
Tachometer
The electric tachometer allows the rider to monitor the engine speed and keep it within the ideal
power range.
CAUTION:
Do not operate the engine in the tachometer
red zone.
Red zone: 11,750 r/min and above
Self-diagnosis devices
This model is equipped with a self-diagnosis device for the following electrical circuits:
Throttle position sensor
Speed sensor
EXUP system
If any of those circuits are defective, the
tachometer will repeatedly display the following
error code:
0 r / min
for
3 seconds
–56–
Circuit-specific
number of r / min
for 2.5 seconds
(See the table
below.)
Current
engine
speed for
3 seconds
ELECTRIC STARTING SYSTEM
ELEC
ELECTRIC STARTING SYSTEM
STARTER MOTOR
5 Nm (0.5 mkg)
7 Nm (0.7 mkg)
Order
1
2
3
4
Job/Part
Removing the starter motor
Rider seat
Fuel tank
Left side cowling
EXUP servomotor
Throttle stop screw
Starter motor lead
Starter motor assembly
Q’ty
Remarks
Remove the parts in the order listed.
Refer to “SEATS” in chapter 3.
Refer to “FUEL TANK” in chapter 3.
Refer to “COWLINGS” in chapter 3.
1
1
1
1
For installation, reverse the removal
procedure.
–57–
ELECTRIC STARTING SYSTEM
ELEC
EB803501
5 Nm (0.5 mkg)
Order
1
2
3
4
5
6
7
8
9
Job/Part
Disassembling the starter motor
Starter motor rear cover
Bearing
Starter motor yoke
O-ring
Armature assembly
Brush
Brush holder
Starter motor front cover
Bearing
Q’ty
Remarks
Disassembly the parts in the order listed.
1
1
1
2
1
2
1
1
1
For assembly, reverse the disassembly
procedure
–58–
ELECTRIC STARTING SYSTEM
ELEC
EB803511
Checking The Starter Motor
1. Check:
S commutator
Dirt Clean with 600 grit sandpaper.
2. Measure:
S commutator diameter a
Out of specification Replace the starter
motor.
Min. commutator diameter
23.5 mm
3. Measure:
S mica undercut a
Out of specification Scrape the mica to the
proper measurement with a hacksaw blade
which has been grounded to fit the commutator.
Mica undercut
1.5 mm
NOTE:
The mica must be undercut to ensure proper operation of the commutator.
4. Measure:
S armature assembly resistances (commutator and insulation)
Out of specification Replace the starter
motor.
a. Measure the armature assembly resistances
with the pocket tester.
Pocket tester
90890-03112
Armature assembly
Commutator resistance 1
Continuity
OK
NO continuity
NG
Insulation resistance 2
Above 1 MΩ at 20_C
b. If any resistance is out of specification, replace the starter motor.
–59–
ELECTRIC STARTING SYSTEM
ELEC
5. Measure:
brush length a
Out of specification Replace the brushes
as a set.
Min. brush length
3.65 mm
6. Measure:
brush spring force
Out of specification Replace the brush
springs as a set.
Brush spring force
5.28 X 7.92 N
7. Check:
gear teeth
Damage/wear Replace the gear.
8. Check:
bearing
oil seal
Damage/wear Replace the defective
part(-s).
EB803701
Assembling The Starter Motor
1. Install:
brush seat 1
NOTE:
Align the tab a on the brush seat with the slot b
in the starter motor front cover.
2. Install:
armature 1
–60–
ELECTRIC STARTING SYSTEM
ELEC
3. Install:
starter motor yoke 2
O-rings 1 New
starter motor rear cover 3
bolts
5 Nm (0.5 mkg)
NOTE:
Align the match marks a on the starter motor
yoke with the match marks b on the front and
rear covers.
–61–
COOLING SYSTEM
EB807000
COOLING SYSTEM
CIRCUIT DIAGRAM
1
5
6
22
28
48
49
50
Main switch
Battery
Main fuse
Thermo unit
Combination meter
Radiator fan motor
Radiator fan motor relay
Radiator fan motor fuse
–62–
ELEC
COOLING SYSTEM
EB807010
ELEC
EB802401
TROUBLESHOOTING
2. Battery
S The radiator fan motor fails to turn.
S The coolant temperature meter needle
fails to move when the engine is warm.
S Check the condition of the battery.
Refer to “CHECKING AND CHARGING
THE BATTERY” in chapter 3.
CAUTION:
Open-circuit voltage
12.8 V or more at 20_C
S If the engine is kept running at over 1,500
rpm for at least one minute with the switch
remaining placed in neutral position and
the throttle valve fully open, even when the
coolant temperature is low enough, the radiator fan motor will start rotating. This,
however, is not trouble.
S Keep hands and other body regions away
to avoid injury.
Check:
1. main, signal system, and radiator fan motor
fuses
2. battery
3. main switch
4. radiator fan motor
5. Fan motor relay
6. Speedometer
7. Thermo unit
8. Wiring
(the entire cooling system)
NOTE:
S Before troubleshooting, remove the following
part(-s).
1) rider seat
2) bottom cowling
3) front cowling inner panels
4) left side cowling
5) windshield
S Troubleshooting with the following special
tool(-s).
S Is the battery OK?
YES
NO
S Clean the battery
terminals.
S Recharge or replace the battery.
EB802411
3. Main switch
S Check the main switch for continuity.
Refer to “CHECKING THE SWITCHES”.
S Is the main switch OK?
YES
NO
Replace
switch.
the
main
EB807400
4. Radiator fan motor
S Disconnect the radiator fan motor coupler
from the wire harness.
S Connect the battery (12 V) as shown.
Battery positive lead blue 1
Battery negative lead black 2
Pocket tester
90890-03112
EB802400
1. Main, signal system and radiator fan
motor fuses
S Check the main, signal system, and radiator
fan motor fuses for continuity.
Refer to “CHECKING THE FUSES” in chapter 3.
S Are the main, signal system, and radiator fan
motor fuses OK?
YES
S Does the radiator fan motor turn?
YES
NO
NO
The radiator fan motor is faulty and must
be replaced.
Replace the fuse(-s).
–63–
COOLING SYSTEM
EB807400
ELEC
EB807402
5. Fan motor relay
7. Thermo unit
S Disconnect the fan motor relay coupler.
S Connect the pocket tester (Ω
1) and battery (12V) to the fan motor relay coupler as
shown.
S Remove the thermo unit from the radiator.
S Connect the pocket tester (Ω 1) to the thermo unit 1 as shown.
S Immerse the thermo unit in a container filled
with coolant 2 .
NOTE:
Make sure that the thermo unit terminals do
not get wet.
Battery positive lead brown 1
Battery negative lead green/black 2
Tester positive prove brown 3
Tester negative prove blue 4
S Place a thermometer 3 in the coolant.
S Slowly heat the coolant, then let it cool to the
specified temperature as indicated in the
table.
S Check the thermo unit for continuity at the
temperatures indicated in the table.
Thermo unit
9.7 X 11.4 kΩ at 50_C
3.4 X 4.0 kΩ at 80_C
1.6 X 1.9 kΩ at 105_C
1.1 X 1.2 kΩ at 120_C
S Does the radiator fan motor relay have continuity between brown and blue?
YES
NO
Replace the fan motor relay.
EB807400
6. Speedometer
S Disconnect the thermo unit coupler.
S Set the main switch to “ON”.
S Connect the green/red 1 and black/blue 2
terminals with a jumper lead 3 as shown.
WARNING
S Handle the thermo unit with special care.
S Never subject the thermo unit to strong
shocks. If the thermo unit is dropped, replace it.
S Does the coolant temperature display “HI”
and warning light comes on?
YES
NO
Thermo unit
23 Nm (2.3 mSkg)
Three bond sealock 10
The speedometer is
faulty and must be repaired.
–64–
COOLING SYSTEM
Does the thermo unit operate properly as described above?
YES
NO
Replace the thermo
unit.
EB807403
8. Wiring
Check the entire cooling system’s wiring.
Refer to “CIRCUIT DIAGRAM”.
Is the cooling system’s wiring properly connected and without defects?
YES
This circuit is OK.
NO
Properly connect or
repair the cooling
system’s wiring.
–65–
ELEC
SELF-DIAGNOSIS
ELEC
EB812000
SELF-DIAGNOSIS
The YZF-R1 features a self-diagnosing system for the following circuit(-s):
throttle position sensor
EXUP
speed sensor
fuel level warning light
If any of these circuits are defective, their respective condition codes will be displayed on the tachometer when the main switch is set to “ON” (irrespective of whether the engine is running or not)
Circuit
Throttle position sensor
Defect(-s)
Disconnected
Short-circuit
Locked
EXUP
Improper connection
Short-circuit
Servomotor is
locked.
Speed sensor
Fuel level
warning light
Disconnected
Short-circuit
Improper connection
Short-circuit
System response
The ignitor unit stays set to the
wide-open throttle ignition timing.
The motorcycle can be ridden.
The tachometer displays the
condition code.
The EXUP valve stays in the open
position for three seconds and
then the servomotor shuts off. The
motorcycle can be ridden.
The tachometer displays the
condition code.
The servomotor’s power supply is
constantly interrupted so that it
will not burn out. The motorcycle
can be ridden.
The tachometer displays the
condition code.
The tachometer displays the
condition code.
Display the condition code on the
fuel level warning light.
Condition code
3,000 r/min
7,000 r/min
4000 r/min
The warning light
will flash eight
times, then go off
for three seconds.
Tachometer display sequence
Revolution
( 103 r / min)
Tachometer display
1 0 r / min ... 3 seconds
2 Condition code ... 2.5 seconds
3 Engine speed ... 3 seconds
Engine speed
Time (seconds)
When more than one item is being monitored, the tachometer needle displays the condition codes in
ascending order, cycling through the sequence repeatedly.
If the engine is stopped, the engine speed 3 is 0 r/min.
–66–
SELF-DIAGNOSIS
ELEC
EB812010
2. Speed sensor
TROUBLESHOOTING
Place the motorcycle on a suitable stand so
that the rear wheel is elecated.
Connect the pocket tester (DC 20V) to the
speed sensor connector.
The tachometer starts to display the selfdiagnosis sequence.
Check:
1. speed sensor
2. fuel level warning light
NOTE:
Troubleshoot
tool(-s).
with
the
Tester (+) lead ³ White 1 terminal
Tester (–) lead ³ Body earth
following
special
Pocket tester
90890-03112
1. Speed sensor
CIRCUIT DIAGRAM
Set the main switch to “ON”.
Turn the rear wheel slowly.
Check the tester voltage (0V - 5V - 0V).
Is the speed sensor OK?
YES
Replace the ignitor
unit.
NO
Replace the speed
sensor.
2. Fuel level warning light
(Refer to signal system)
16 Ignitor unit
21 Speed sensor
1. Wire harness
Check the wire harness for continuity.
Refer to “CIRCUIT DIAGRAM”.
Is the wire harness OK?
YES
NO
Repair or replace the
wire harness.
–67–
YZF-R1 WIRING DIAGRAM (For EUR)
COLOR CODE
B .....
Br . . . .
Ch . . .
Dg . . .
G ....
Gy . . .
L .....
O ....
P .....
R.....
black
brown
chocolate
dark green
green
gray
blue
orange
pink
red
Sb . . . .
W ....
Y .....
B/ L . . .
B/ R . . .
B/ W . .
B/ Y . . .
Br/ L . .
Br/ R . .
Br/ W .
sky blue
white
yellow
black/ blue
black/ red
black/ white
black/ yellow
brown/ blue
brown/ red
brown/ white
G/R . .
G/W . .
G/Y . .
L/B . . .
L/R . . .
L/W . .
L/Y . . .
O/R . .
R/ B . . .
R/ G . .
green / red
green / white
green / yellow
blue/ black
blue/ red
blue/ white
blue/ yellow
orange / red
red / black
red / green
R/ L . . .
R/ W . .
R/ Y . . .
W/ B . .
W/ G . .
W/ Y . .
Y/ B . . .
Y/ L . . .
red / blue
red / white
red / yellow
white/ black
white/ green
white/ yellow
yellow/ black
yellow/ blue
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
Main switch
Backup fuse (odometer)
Rectifier/ regulator
Generator
Battery
Main fuse
Starter relay
Starter motor
Relay unit
Starting circuit cutoff relay
Fuel pump relay
Fuel pump
Sidestand switch
EXUP servomotor
Throttle position sensor
Ignition unit
Ignition coil
Spark plug
Pickup coil
Neutral switch
Speed sensor
Thermo unit
Meter assembly
Fuel level indicator light
Oil level warning light
Neutral indicator light
Tachometer
Combination meter
Coolant temperature meter
High beam indicator light
Turn signal indicator light
Meter light
Fuel sender
Left handlebar switch
Pass switch
Dimmer switch
Horn switch
Horn
Clutch switch
Turn signal switch
Turn signal relay
Rear turn signal light
Front turn signal light
Headlight
Auxiliary light
Headlight relay
Tail/ brake light
Radiator fan motor
Radiator fan motor relay
Radiator fan motor fuse
Headlight fuse
Signaling system fuse
CYCLELOCK (option)
Ignition fuse
Engine oil level switch
Rear brake light switch
Right handlebar switch
Front brake light switch
Lights switch
Engine stop switch
Start switch
YZF-R1 WIRING DIAGRAM (For OCE)
COLOR CODE
B .....
Br . . . .
Ch . . .
Dg . . .
G ....
Gy . . .
L .....
O ....
P .....
R.....
black
brown
chocolate
dark green
green
gray
blue
orange
pink
red
Sb . . . .
W ....
Y .....
B/ L . . .
B/ R . . .
B/ W . .
B/ Y . . .
Br/ L . .
Br/ R . .
Br/ W .
sky blue
white
yellow
black/ blue
black/ red
black/ white
black/ yellow
brown/ blue
brown/ red
brown/ white
G/R . .
G/W . .
G/Y . .
L/B . . .
L/R . . .
L/W . .
L/Y . . .
O/R . .
R/ B . . .
R/ G . .
green / red
green / white
green / yellow
blue/ black
blue/ red
blue/ white
blue/ yellow
orange / red
red / black
red / green
R/ L . . .
R/ W . .
R/ Y . . .
W/ B . .
W/ G . .
W/ Y . .
Y/ B . . .
Y/ L . . .
red / blue
red / white
red / yellow
white/ black
white/ green
white/ yellow
yellow/ black
yellow/ blue
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
Main switch
Backup fuse (odometer)
Rectifier/ regulator
Generator
Battery
Main fuse
Starter relay
Starter motor
Relay unit
Starting circuit cutoff relay
Fuel pump relay
Fuel pump
Sidestand switch
EXUP servomotor
Throttle position sensor
Ignition unit
Ignition coil
Spark plug
Pickup coil
Neutral switch
Speed sensor
Thermo unit
Meter assembly
Fuel level indicator light
Oil level warning light
Neutral indicator light
Tachometer
Combination meter
Coolant temperature meter
High beam indicator light
Turn signal indicator light
Meter light
Left handlebar switch
Pass switch
Dimmer switch
Horn switch
Horn
Clutch switch
Turn signal switch
Turn signal relay
Fuel sender
Rear turn signal light
Front turn signal light
Headlight
Headlight relay
Tail/ brake light
Radiator fan motor
Radiator fan motor relay
Radiator fan motor fuse
Headlight fuse
Signaling system fuse
Ignition fuse
Engine oil level switch
Rear brake light switch
Right handlebar switch
Front brake light switch
Engine stop switch
Start switch
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