Yamaha R1 Series 2015 Service Manual

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2015

SERVICE MANUAL

YZF-R1

YZF-R1F

YZF-R1M

YZF-R1MF

2CR-28197-E0

Table of Contents

Troubleshooting

Summary of Contents for Yamaha R1 Series 2015

Page 1 2015 SERVICE MANUAL YZF-R1 YZF-R1F YZF-R1M YZF-R1MF 2CR-28197-E0...
Page 3 EAS20002 YZF-R1/YZF-R1F YZF-R1M/YZF-R1MF SERVICE MANUAL ©2015 by Yamaha Motor Co., Ltd. First edition, February 2015 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited.
Page 4 EAS20003 IMPORTANT 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 man- ual. 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.
Page 5: How To Use This Manual
EAS20004 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. •...
Page 6 EAS20005 SYMBOLS The following symbols are used in this manual for easier understanding. The following symbols are not relevant to every vehicle. SYMBOL DEFINITION SYMBOL DEFINITION Serviceable with engine mounted Gear oil Filling fluid Molybdenum disulfide oil Lubricant Brake fluid Special tool Wheel bearing grease Tightening torque...
Page 7: Table Of Contents
TABLE OF CONTENTS EAS10003 GENERAL INFORMATION SPECIFICATIONS PERIODIC CHECKS AND ADJUSTMENTS CHASSIS ENGINE COOLING SYSTEM FUEL SYSTEM ELECTRICAL SYSTEM TROUBLESHOOTING...
Page 9: Table Of Contents
VEHICLE IDENTIFICATION NUMBER ............1-1 MODEL LABEL...................1-1 FEATURES .......................1-2 OUTLINE OF THE FI SYSTEM..............1-2 FI SYSTEM....................1-3 YCC-T (Yamaha Chip Controlled Throttle)/YCC-I (Yamaha Chip Controlled Intake) ..............1-5 ELECTRONIC CONTROL-RELATED FEATURES........1-8 OUTLINE OF THE UBS ................1-13 OUTLINE OF THE ABS................1-17 ABS COMPONENT FUNCTIONS ............1-22 UBS AND ABS OPERATION ..............1-26...
Page 10: Vehicle Identification Number
IDENTIFICATION EAS20007 IDENTIFICATION EAS30002 VEHICLE IDENTIFICATION NUMBER The vehicle identification number “1” is stamped into the right side of the steering head pipe. EAS30003 MODEL LABEL The model label “1” is affixed to the frame under the passenger seat. This information will be needed to order spare parts.
Page 11 FEATURES EAS20008 FEATURES EAS30005 OUTLINE OF THE FI SYSTEM The main function of a fuel supply system is to provide fuel to the combustion chamber at the optimum air-fuel ratio in accordance with the engine operating conditions and the atmospheric temperature. In the conventional carburetor system, the air-fuel ratio of the mixture that is supplied to the combustion chamber is created by the volume of the intake air and the fuel that is metered by the jet used in the respective carburetor.
Page 12: Fi System
FEATURES EAS30617 FI SYSTEM The fuel pump delivers fuel to the fuel injector via the fuel filter. The pressure regulator maintains the fuel pressure that is applied to the fuel injector at a certain level. Accordingly, when the energizing signal from the ECU energizes the fuel injector, the fuel passage opens, causing the fuel to be injected into the intake manifold only during the time the passage remain open.
Page 13 FEATURES Illustration is for reference only. C. Control system 1. Secondary injector 2. Fuel pump 3. Primary injector 4. Cylinder identification sensor 5. ECU (Engine Control Unit) 6. Throttle position sensor 7. Accelerator position sensor 8. Rear wheel sensor 9. Intake air temperature sensor 10.IMU (Inertial Measurement Unit) 11.O sensor...
Page 14: Ycc-T (Yamaha Chip Controlled Throttle)/Ycc-I Yamaha Chip Controlled Intake)
Electronic control throttle systems have been used on automobiles, but Yamaha has de- veloped a faster, more compact system specifically for the needs of a sports motorcycle. The Yamaha- developed system has a high-speed calculating capacity that produces computations of running con- ditions every 1/1000th of a second.
Page 15 FEATURES Aims and advantages of using YCC-I system • Improved power band By using a dual intake funnel system, YCC-I optimizes the effectiveness of the fuel injection system to deliver an incredibly precise air/fuel mixture to the combustion chamber. This degree of intake vol- ume control gives both improved low to mid-range power, as well as improved power in the higher rpm range.
Page 16 FEATURES YCC-T/YCC-I system outline 1. Throttle position sensor 2. Throttle servo motor 3. Accelerator position sensor 4. ECU (Engine Control Unit) 5. Sensor input 6. Neutral switch 7. Crankshaft position sensor 8. Rear wheel sensor 9. Coolant temperature sensor 10.Atmospheric pressure sensor 11.Intake funnel servo motor...
Page 17 FEATURES EAS31625 ELECTRONIC CONTROL-RELATED FEATURES Digital instrument panel with TFT liquid crystal display All of the instrument function displays have been concentrated into a single 4.2-inch screen that adopts a fully transmissive Thin Film Transistor (TFT) liquid crystal display. A white background and a black background can be selected for the background illumination, and the display also features automatic brightness adjustment activated by a sensor that measures ambient light conditions.
Page 18 FEATURES The “Track” mode displays information needed in racing. The tachometer displays the over-8,000 rpm to redline range used most often in racing with a high degree of clarity and detail. This mode features high priority displays of lap number, lap times as well as a stopwatch function, all useful items for racing. Each display also has a memory function that enables lap-by-lap time verification for quick post-race analysis.
Page 19 FEATURES Timing of each control system’s activation (Launch Control System) (Traction Control System) (Slide Control System) (Lift Control System) (Quick Shift System) a. Start d. Corner e. Exit b. Accelerate f. Accelerate c. Decelerate New Traction Control System (TCS) that includes depth of banking as a parameter A new Traction Control System (TCS) is adopted to effectively bring out the drive force potential of the rear tire during acceleration.
Page 20 First ABS and Unified Brake System on a Yamaha supersport model Both an Anti-lock Brake System (ABS), with its contribution to running performance, and Yamaha’s Uni- fied Brake System, with its capacity to inhibit unwanted machine motion during braking are adopted.
Page 21 A power mode selection system (PWR) for a choice of running modes to fit rider preferences and the riding environment, and also the YAMAHA Ride Control (YRC) system are adopted. The PWR system consists of four different control maps to regulate throttle valve opening depending on the degree of throttle opening, thus providing the user with a selection of modes to fit his/her prefer- ences and the riding environment.
Page 22 FEATURES EAS30853 OUTLINE OF THE UBS This model is equipped with a unified brake system (UBS) that operates the rear brake when the brake lever is squeezed. When the brake lever is squeezed, the rear brake force is controlled electronically according to the brake lever input (hydraulic pressure) and the rear brake force is adjusted depending on the bank angle during cornering.
Page 23 FEATURES Brake pedal only operated b. No automatic pressurization a. Input • Brake lever input and brake pedal input: Front braking and rear braking (with and without UBS oper- ation) Brake lever and brake pedal both operated A. Brake lever is operated before brake pedal B.
Page 24 FEATURES UBS diagram 1. Rear brake master cylinder a. Input 2. Front brake master cylinder b. Pressurization 3. Hydraulic unit assembly (ABS ECU) c. Pressurization (hydraulic pump pressuriza- tion by UBS) 4. Front brake caliper (right) 5. Front brake caliper (left) 6.
Page 25 FEATURES When vehicle is stopped using brake lever only b. Automatic pressurization A. Deceleration c. Input maintained B. Vehicle stopped C. Brake lever released, then squeezed again, d. Pressurization maintained after vehicle stops e. Brake lever released, then squeezed again f.
Page 26: Outline Of The Abs
FEATURES d. Bank angle coefficient a. Hydraulic pressure distribution e. Coefficient (%) b. Rear brake output f. Bank angle c. Front brake input EAS30683 OUTLINE OF THE ABS 1. This model is equipped with the latest, advanced type of ABS, which has improved feeling during operation and smoother braking than previous ABS brakes.
Page 27 9. Rear wheel sensor rotor 3. ABS ECU fuse 10.Rear brake caliper 4. ABS solenoid fuse 5. Front wheel sensor rotor 11.Yamaha diagnostic tool coupler 12.ABS motor fuse 6. Front wheel sensor Useful terms • Wheel speed: The rotation speed of the front and rear wheels.
Page 28 FEATURES • Slip ratio: When the brakes are applied, slipping occurs between the tires and the road surface. This causes a difference between the wheel speed and the chassis speed. Slip ratio is the value that shows the rate of wheel slippage and is defined by the following formula. Slip ratio = (Chassis speed –...
Page 29 FEATURES a. Chassis speed d. Depressurizing phase e. Pressurizing phase b. Wheel speed c. Brake force ABS operation and vehicle control If the ABS starts operating, there is a tendency of the wheel to lock, and the vehicle is approaching the limit of control.
Page 30 Slip ratio b. Brake force Electronic ABS features The Yamaha ABS (Anti-lock Brake System) has been developed with the most advanced electronic technology. The ABS also includes a highly developed self-diagnosis function. The ABS has been designed to op- erate as a conventional brake system if the ABS malfunctions.
Page 31: Abs Component Functions
FEATURES ABS block diagram 10.Check valve 1. Front brake master cylinder 11.Buffer chamber 2. Rear brake master cylinder 12.Inlet solenoid valve 3. Hydraulic unit assembly 13.Outlet solenoid valve 4. Rear brake master cylinder pressure sensor 14.Rear brake caliper pressure sensor 5.
Page 32 FEATURES 3. At low speed 6. Wheel sensor rotor 7. Voltage 4. At high speed 8. Time 5. Wheel sensor ABS warning light The ABS warning light “1” comes on to warn the rider if a malfunction in the ABS occurs. When the main switch is turned to “ON”, the ABS warning light comes on during the ABS self-diagnosis to check the electrical circuit of the light.
Page 33 FEATURES Hydraulic unit assembly The hydraulic unit assembly “1” is composed of hydraulic control valves (outlet solenoid valves, inlet solenoid valves, a shuttle solenoid valve, and a separation solenoid valve), buffer chambers, hydraulic pumps, an ABS motor, hydraulic pressure sensors (front brake master cylinder pressure sensor, front brake caliper pressure sensor, rear brake master cylinder pressure sensor, and rear brake caliper pres- sure sensor), and an ABS ECU.
Page 34 10.Front brake light switch 27.Speedometer 11.Rear brake light switch 28.IMU (Inertial Measurement Unit) 12.Tail/brake light 13.Hydraulic unit assembly 29.Yamaha diagnostic tool coupler 30.Rear wheel sensor 14.ABS ECU 31.Front wheel sensor 15.Solenoid relay 16.ABS motor relay The necessary actions are confirmed using the monitor circuit and control signals are transmitted to the hydraulic unit assembly.
Page 35: Ubs And Abs Operation
FEATURES • The ABS performs a self-diagnosis test for a few seconds each time the vehicle first starts off after the main switch was turned on. During this test, a “clicking” noise can be heard from under the seat, and if the brake lever or brake pedal is even slightly operated, a vibration can be felt at the lever and pedal, but these do not indicate a malfunction.
Page 36 FEATURES 8. Inlet solenoid valve 1. Front brake master cylinder 9. Outlet solenoid valve 2. Brake lever 10.Rear brake caliper 3. Rear brake master cylinder 11.Front brake calipers 4. Brake pedal 5. Separation solenoid valve A. Pressurize 6. Hydraulic pump 7.
Page 37 FEATURES 12.Buffer chamber 1. Front brake master cylinder 13.Rear brake caliper 2. Brake lever 14.Front brake calipers 3. Rear brake master cylinder 4. Brake pedal A. Pressurize 5. Separation solenoid valve B. Depressurize 6. Shuttle solenoid valve 7. ABS motor a.
Page 38 FEATURES sensor, front brake caliper pressure sensor, rear brake master cylinder pressure sensor, and rear brake caliper pressure sensor. 13.Check valve 1. Front brake master cylinder 14.Buffer chamber 2. Brake lever 15.Rear brake caliper pressure sensor 3. Rear brake master cylinder 16.Front brake caliper pressure sensor 4.
Page 39: Abs Warning Light And Operation
FEATURES 15.Rear brake caliper pressure sensor 1. Front brake master cylinder 16.Front brake caliper pressure sensor 2. Brake lever 17.Rear brake caliper 3. Rear brake master cylinder 18.Front brake calipers 4. Brake pedal 5. Rear brake master cylinder pressure sensor A.
Page 40: Abs And Ubs Function
FEATURES EAS30983 ABS AND UBS FUNCTION EWA17260 WARNING • When hydraulic control is performed by the ABS, the brake system alerts the rider that the wheels have a tendency to lock by generating a reaction-force pulsating action in the brake lever or brake pedal.
Page 41: Glossary
SCU - Suspension Control Unit 6. Clock TCS - Traction Control System 7. Revolution peak hold indicator UBS - Unified Brake System 8. Front brake pressure indicator YRC - Yamaha Ride Control 9. Acceleration indicator EAS31707 10.Transmission gear display DISPLAY 11.YRC items MODE/PWR/TCS/SCS The display has two different main screen dis- 12.Information display...
Page 42 FEATURES to “Unit” on page 1-41.) flash for five seconds. (For STREET MODE, Tachometer if both items are resettable items, the top item The tachometer shows the engine speed, as will flash first. Scroll down to select the bot- measured by the rotational velocity of the crank- tom item.) shaft, in revolutions per minute (r/min).
Page 43 FEATURES ERS indicator (YZF-R1M) left to right and highlight the item you want to adjust. This icon shows the current ERS mode. (Refer to “YRC Setting” on page 1-37 and “ERS (YZF- R1M)” on page 1-39 to change the registered ERS mode or adjust ERS setting levels.) The ERS indicator will flash should the SCU need to be reset, but this does not indicate a...
Page 44 FEATURES Error mode 4. When the lap timer has been activated, press the PASSING/LAP switch to start the lap tim- 1 2 3 • Set the information display to FASTEST or AV- ERAGE for additional lap time information. • Accessing the MENU screen will automatically E r r 1000 r/min stop the lap timer.
Page 45 FEATURES 4. If one or both of the standard keys do not start Set the multi-function display “Display Setting” the engine, re-register the standard keys. If window items. the display indicates any fault codes, note the “Brightness” Adjust screen brightness. code number, and then check the vehicle.
Page 46 FEATURES 3. Select STREET MODE or TRACK MODE (or 1. PWR-1 select the triangle mark to exit). 2. PWR-2 3. PWR-3 4. PWR-4 5. Throttle valve opening 6. Throttle grip operation This model uses a variable traction control sys- tem. For each setting level, the further the vehi- cle is leaned over, the greater the amount of traction control (system intervention) is applied.
Page 47 FEATURES of system intervention. 1. System intervention 1. System intervention 2. Wheel lift 2. Sideward slide [To customize a YRC mode or adjust a YRC item] LCS can be set to 1, 2, or OFF. Setting level 2 1. From the MENU screen, select “YRC Set- more strongly controls power engine output, ting”.
Page 48 FEATURES [To adjust the ERS mode settings] 12 : 00 YRC Setting km/h 12 : 00 YRC Setting km/h A - 1 A - 1 A - 2 A - 2 A - 3 A - 3 M - 1 M - 1 M - 2 M - 2...
Page 49 FEATURES values for the same item are automatically linked). • M-1, M-2, M-3 are not linked and can be inde- pendently set. 4. To adjust other ERS mode suspension set- tings, repeat from step 2. When finished, se- lect the “ ”...
Page 50 FEATURES “Logging” (for CCU-equipped models) [To reset a maintenance item] Vehicle and riding information can be recorded 1. From the MENU screen, select “Mainte- (logged) and this data can be accessed with a nance”. smart device. (Refer to “CONNECTING TO THE CCU (for YZF-R1M)”...
Page 51 FEATURES STREET MODE and TRACK MODE display background colors to black or white for both day km/h and night settings. A photo sensor equipped in the instrument panel detects lighting conditions and will automatically change the display be- tween its day and night settings. The photo sen- sor also controls a subtle automatic brightness adjustment function within both day and night modes to suit ambient light conditions.
Page 52 FEATURES module. 3. Select “ON” to have the indicator light steadi- ly, “OFF” to turn the indicator off, or “Flash” to have the shift indicator flash when the indica- tor start threshold has been reached. “Shift indicator” The shift indicator module contains the following items.
Page 53 FEATURES Select “Shift IND Brightness”, then use the 2. Select “IND Mode”. wheel switch to adjust the setting. Short push the wheel switch to confirm the setting and exit. 3. Select ON to turn the tachometer color dis- play mode on (or select OFF to turn this func- “Tach IND Setting”...
Page 54 FEATURES Green bar start setting range: 8000–10000 r/min. 6. Select “Tach IND 2nd”. 2. Select “IND Mode” and then select ON (to turn on the indicator) or OFF (to turn off the in- dicator). 7. Set the orange color starting r/min by rotating and then short pushing the wheel switch.
Page 55 FEATURES 12 : 00 A - 1 LC LCS 1000 r/min × 12 34 GEAR LATEST 7890 km/h MODE - 5. Select the desired information display item 1. Information display item (TRACK MODE) with the wheel switch. [To set the display groups] The information display items which can be se- 1.
Page 56 FEATURES 2. Select the desired brightness level by rotating 4. The minutes figure will become highlighted. the wheel switch, and then short push the wheel switch to fix the setting. 5. Set the minutes figure by rotating and then short push the wheel switch. “Clock”...
Page 57: Replacement Parts
5. Keep all parts away from any source of fire. EAS30007 REPLACEMENT PARTS Use only genuine Yamaha parts for all replace- ments. Use oil and grease recommended by Yamaha for all lubrication jobs. Other brands may be similar in function and appearance, but inferior in quality.
Page 58: Circlips
IMPORTANT INFORMATION and replace damaged or distorted circlips. Al- EAS30009 LOCK WASHERS/PLATES AND COTTER ways replace piston pin clips after one use. PINS When installing a circlip “1”, make sure the After removal, replace all lock washers/plates sharp-edged corner “2” is positioned opposite “1”...
Page 59 BASIC SERVICE INFORMATION EAS20010 BASIC SERVICE INFORMATION EAS30013 QUICK FASTENERS Rivet type 1. Remove: • Quick fastener To remove the quick fastener, push its pin with a screwdriver, then pull the fastener out. Screw type 1. Remove: • Quick fastener To remove the quick fastener, loosen the screw with a screwdriver, then pull the fastener out.
Page 60: Electrical System
BASIC SERVICE INFORMATION If a battery lead is difficult to disconnect due to rust on the battery terminal, remove the rust us- ing hot water. EAS30014 ELECTRICAL SYSTEM Electrical parts handling ECA16600 NOTICE ECA16760 NOTICE Never disconnect a battery lead while the en- Be sure to connect the battery leads to the gine is running;...
Page 61 BASIC SERVICE INFORMATION ECA16610 NOTICE When resetting the ECU by turning the main Turn the main switch to “OFF” before dis- switch to “OFF”, be sure to wait approximately connecting or connecting an electrical com- 5 seconds before turning the main switch back ponent.
Page 62 BASIC SERVICE INFORMATION ECA16640 NOTICE For waterproof couplers, never insert the tester probes directly into the coupler. When performing any checks using a waterproof coupler, use the specified test harness or a suitable commercially available test har- ness. Checking the connections Check the leads, couplers, and connectors for stains, rust, moisture, etc.
Page 63 BASIC SERVICE INFORMATION 2. Check: 4. Check: • Lead • Continuity • Coupler (with the pocket tester) • Connector Pocket tester Moisture Dry with an air blower. 90890-03112 Rust/stains Connect and disconnect sev- Analog pocket tester eral times. YU-03112-C • If there is no continuity, clean the terminals. •...
Page 64 BASIC SERVICE INFORMATION The resistance values shown were obtained at the standard measuring temperature of 20 C (68 F). If the measuring temperature is not 20 C (68 F), the specified measuring conditions will be shown. Intake air temperature sensor re- sistance 5.40–6.60 k at 0 C (32 F) 290–390...
Page 65 SPECIAL TOOLS EAS20012 SPECIAL TOOLS The following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools as this will help prevent damage caused by the use of inappropriate tools or improvised techniques. Special tools, part numbers or both may differ depending on the country. When placing an order, refer to the list provided below to avoid any mistakes.
Page 66 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Radiator cap tester adapter 6-2, 6-3 90890-01352 Pressure tester adapter YU-33984 YU-33984 Damper rod holder (22 mm) 4-113, 4-115 90890-01365 Crankshaft protector 5-36 90890-01382 Crankshaft protector YM-01382 Steering nut wrench 3-21, 4-102 90890-01403 Exhaust flange nut wrench YU-A9472...
Page 67 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Rod puller attachment (M10) 4-85, 4-87 90890-01436 Universal damping rod bleeding tool set YM-A8703 YM-A8703 Rod puller 4-85, 4-87 90890-01437 Universal damping rod bleeding tool set YM-A8703 YM-A8703 Fork spring compressor 4-81, 4-87 90890-01441 Fork spring compressor YM-01441...
Page 68 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Damper rod holder 4-82, 4-84 90890-01506 Damper rod holder YM-01506 Ring nut wrench 4-113, 4-115 90890-01507 Ring nut wrench YM-01507 Drive chain cut & rivet tool 4-117, 4-119 90890-01550 Drive chain cut & rivet tool YM-01550 Wheel bearing ring nut tool 4-38, 4-39...
Page 69 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Compression gauge 90890-03081 90890-03081 Engine compression tester YU-33223 YU-33223 Vacuum gauge 90890-03094 Vacuummate YU-44456 YU-44456 Pocket tester 1-54, 8-179, 90890-03112 8-180, 8-184, Analog pocket tester 8-185, 8-186, YU-03112-C 8-187, 8-188, 8-190, 8-191, 8-192, 8-194, 8-195, 8-196 Oil pressure gauge set...
Page 70 8-194 90890-03208 Test harness– speed sensor (3P) YU-03208 Fuel injector pressure adapter 7-14 90890-03210 Fuel injector pressure adapter YU-03210 Yamaha diagnostic tool 3-12, 4-71, 4-72, 90890-03239 8-53, 8-131, 8-150 Valve spring compressor 5-17, 5-20, 5-28, 90890-04019 5-34 Valve spring compressor...
Page 71 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Universal clutch holder 5-56, 5-60 90890-04086 Universal clutch holder YM-91042 Valve guide remover (ø5) 5-30 90890-04097 Valve guide remover (5.0 mm) YM-04097 Valve guide installer (ø5) 5-30 90890-04098 Valve guide installer (5.0 mm) YM-04098 Valve guide reamer (ø5) 5-30...
Page 72 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Mechanical seal installer 6-12 90890-04132 Water pump seal installer YM-33221-A 15mm pin type rotor holding tool 5-36, 5-37 90890-04171 YM-04171 Piston pin clip insertion tool 5-80 90890-04173 YM-04173 Piston pin clip installer tool 5-81 90890-04174 YM-04174...
Page 73 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Yamaha bond No. 1215 5-37, 5-67 90890-85505 (Three bond No.1215®) 1-64...
Page 74 SPECIAL TOOLS 1-65...
Page 75 SPECIFICATIONS GENERAL SPECIFICATIONS................2-1 ENGINE SPECIFICATIONS ................2-2 CHASSIS SPECIFICATIONS ................2-7 ELECTRICAL SPECIFICATIONS ..............2-11 TIGHTENING TORQUES ................2-14 GENERAL TIGHTENING TORQUE SPECIFICATIONS......2-14 ENGINE TIGHTENING TORQUES............2-15 CHASSIS TIGHTENING TORQUES............2-22 LUBRICATION POINTS AND LUBRICANT TYPES........2-27 ENGINE....................2-27 CHASSIS....................2-28 LUBRICATION SYSTEM CHART AND DIAGRAMS ........2-31 ENGINE OIL LUBRICATION CHART ............2-31 LUBRICATION DIAGRAMS ..............2-33 COOLING SYSTEM DIAGRAMS ..............2-47 CABLE ROUTING ..................2-51...
Page 76 GENERAL SPECIFICATIONS EAS20013 GENERAL SPECIFICATIONS Model Model YZF-R1 2CR1 (AUS)(AUT)(BEL)(CHE)(CYP) (CZE)(DEU)(DNK)(ESP)(FIN)(FRA)(GBR) (GRC)(HRV)(HUN)(IRL)(ISR)(ITA)(NLD)(NOR) (POL)(PRT)(SVK)(SVN)(SWE)(TUR) YZF-R1 2CR2 (BEL)(FRA) YZF-R1 2CR6 (AUS) YZF-R1M 2KS1 (AUS)(AUT)(BEL)(CHE)(CYP) (CZE)(DEU)(DNK)(ESP)(FIN)(FRA)(GBR) (GRC)(HRV)(HUN)(IRL)(ISR)(ITA)(NLD)(NOR) (POL)(PRT)(SVK)(SVN)(SWE)(TUR) YZF-R1M 2KS2 (BEL)(FRA) YZF-R1M 2KS6 (AUS) YZF-R1M 2KS7 (RUS) Dimensions Overall length 2055 mm (80.9 in) Overall width 690 mm (27.2 in) Overall height...
Page 77 ENGINE SPECIFICATIONS EAS20014 ENGINE SPECIFICATIONS Engine Engine type Liquid cooled 4-stroke, DOHC Displacement 998 cm³ Cylinder arrangement Inline 4-cylinder Bore stroke 79.0 50.9 mm (3.11 2.00 in) Compression ratio 13.0 : 1 Standard compression pressure (at sea level) 1450 kPa/250 r/min (14.5 kgf/cm²/250 r/min, 206.2 psi/250 r/min) Minimum–maximum 1260–1630 kPa/250 r/min (12.6–16.3...
Page 78 ENGINE SPECIFICATIONS Coolant reservoir (up to the maximum level 0.25 L (0.26 US qt, 0.22 Imp.qt) mark) Radiator cap opening pressure 107.9–137.3 kPa (1.08–1.37 kgf/cm², 15.6–19.9 psi) Thermostat Valve opening temperature 71.0 C (159.80 F) Valve full open temperature 85.0 C (185.00 F) Valve lift (full open) 8.0 mm (0.31 in) Radiator core...
Page 79 ENGINE SPECIFICATIONS Valve head diameter (exhaust) 26.40–26.60 mm (1.0394–1.0472 in) Valve seat contact width (intake) 0.90–1.10 mm (0.0354–0.0433 in) Limit 1.6 mm (0.06 in) Valve seat contact width (exhaust) 1.10–1.30 mm (0.0433–0.0512 in) Limit 1.8 mm (0.07 in) Valve stem diameter (intake) 4.975–4.990 mm (0.1959–0.1965 in) Limit 4.960 mm (0.1953 in)
Page 80 ENGINE SPECIFICATIONS Ring type Barrel End gap (installed) 0.15–0.25 mm (0.0059–0.0098 in) Limit 0.50 mm (0.0197 in) Ring side clearance 0.030–0.065 mm (0.0012–0.0026 in) Limit 0.115 mm (0.0045 in) 2nd ring Ring type Taper End gap (installed) 0.65–0.80 mm (0.0256–0.0315 in) Limit 1.15 mm (0.0453 in) Ring side clearance...
Page 81 ENGINE SPECIFICATIONS Operation Left foot operation Gear ratio 2.600 (39/15) 2.176 (37/17) 1.842 (35/19) 1.579 (30/19) 1.381 (29/21) 1.250 (30/24) Main axle runout limit 0.08 mm (0.0032 in) Drive axle runout limit 0.08 mm (0.0032 in) Shifting mechanism Shift fork guide bar bending limit 0.100 mm (0.0039 in) Shift fork thickness (L, C) 5.79–5.87 mm (0.2280–0.2311 in)
Page 82 CHASSIS SPECIFICATIONS EAS20015 CHASSIS SPECIFICATIONS Chassis Frame type Diamond Caster angle 24.00 Trail 102 mm (4.0 in) Front wheel Wheel type Cast wheel Rim size 17M/C x MT3.50 Rim material Magnesium Wheel travel 120 mm (4.7 in) Radial wheel runout limit 1.0 mm (0.04 in) Lateral wheel runout limit 0.5 mm (0.02 in)
Page 83 CHASSIS SPECIFICATIONS Front 250 kPa (2.50 kgf/cm², 36 psi) Rear 290 kPa (2.90 kgf/cm², 42 psi) High-speed riding Front 250 kPa (2.50 kgf/cm², 36 psi) Rear 290 kPa (2.90 kgf/cm², 42 psi) Front brake Type Dual disc brake Operation Right hand operation Front disc brake Disc outside diameter thickness...
Page 84 CHASSIS SPECIFICATIONS Inner tube outer diameter 43.0 mm (1.69 in) Inner tube bending limit 0.2 mm (0.01 in) Recommended oil YZF-R1 Suspension oil M1 or equivalent YZF-R1M Suspension oil M1 or Ohlins R&T 43 Quantity YZF-R1 368.0 cm³ (12.44 US oz, 12.98 Imp.oz) YZF-R1M 405.0 cm³...
Page 85 CHASSIS SPECIFICATIONS Maximum YZF-R1 85.5 mm (3.37 in) YZF-R1M 9.0 mm (0.35 in) Rebound damping adjusting positions Minimum YZF-R1 23 click(s) out YZF-R1M ERS Standard YZF-R1 12 click(s) out YZF-R1M ERS Maximum YZF-R1 0 click(s) out YZF-R1M ERS *With the adjusting screw fully turned in Compression damping setting (for fast compression damping) Minimum YZF-R1 5.5 turn(s) out...
Page 86 ELECTRICAL SPECIFICATIONS EAS20016 ELECTRICAL SPECIFICATIONS Voltage System voltage 12 V Ignition system Ignition system Ignition timing (B.T.D.C.) 5.0 1300 r/min Engine control unit Model/manufacturer YZF-R1 TBDFK1/DENSO (AUS)(AUT)(BEL) (CHE)(CYP)(CZE)(DEU)(DNK)(ESP)(FIN) (FRA)(GBR)(GRC)(HRV)(HUN)(IRL)(ISR)(ITA) (NLD)(NOR)(POL)(PRT)(SVK)(SVN)(SWE) (TUR) YZF-R1 TBDFR8/DENSO (BEL)(FRA) YZF-R1M TBDFK1/DENSO (AUS)(AUT)(BEL) (CHE)(CYP)(CZE)(DEU)(DNK)(ESP)(FIN) (FRA)(GBR)(GRC)(HRV)(HUN)(IRL)(ISR)(ITA) (NLD)(NOR)(POL)(PRT)(RUS)(SVK)(SVN) (SWE)(TUR) YZF-R1M TBDFR8/DENSO (BEL)(FRA) Pickup coil resistance...
Page 87 ELECTRICAL SPECIFICATIONS Indicator light Neutral indicator light Turn signal indicator light High beam indicator light Fuel level warning light Engine trouble and system warning light ABS warning light Oil pressure and coolant temperature warning light Immobilizer system indicator light Shift timing indicator light Stability control indicator light Starter motor Power output...
Page 88 ELECTRICAL SPECIFICATIONS Fuel injection system fuse 15.0 A ABS motor fuse 30.0 A ABS ECU fuse 7.5 A ABS solenoid fuse 15.0 A Terminal fuse 1 2.0 A Backup fuse 7.5 A Electronic throttle valve fuse 7.5 A SCU fuse YZF-R1M 7.5 A Spare fuse 15.0 A...
Page 89 TIGHTENING TORQUES EAS20017 TIGHTENING TORQUES EAS30015 GENERAL TIGHTENING TORQUE SPECIFICATIONS This chart specifies tightening torques for stan- dard fasteners with a standard ISO thread pitch. Tightening torque specifications for special com- ponents or assemblies are provided for each chapter of this manual. To avoid warpage, tight- en multi-fastener assemblies in a crisscross pat- tern and progressive stages until the specified tightening torque is reached.
Page 90 TIGHTENING TORQUES EAS30016 ENGINE TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Spark plug 13 Nm (1.3 m·kgf, 9.4 ft·lbf) Spark plug (new) 18 Nm (1.8 m·kgf, 13 ft·lbf) Exhaust pipe nut 20 Nm (2.0 m·kgf, 14 ft·lbf) Exhaust pipe joint bolt 20 Nm (2.0 m·kgf, 14 ft·lbf) Exhaust chamber bolt 20 Nm (2.0 m·kgf, 14 ft·lbf)
Page 91 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Oil pump drive chain guide bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Oil pipe 1 bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Oil strainer bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Relief valve assembly bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Oil delivery pipe 2 bolt...
Page 92 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Timing chain cover bolt See TIP. Timing chain sprocket bolt 72 Nm (7.2 m·kgf, 52 ft·lbf) Oil pipe 3 bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Oil pipe 2 bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Cylinder head bolt See TIP.
Page 93 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size l=50 mm (1.97 in) Crankcase bolt See TIP. l=50 mm (1.97 in) Crankcase bolt See TIP. l=40 mm (1.57 in) Crankcase bolt See TIP. Plug (oil gallery) 8 Nm (0.8 m·kgf, 5.8 ft·lbf) Plug bolt (balancer shaft end) 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Oil nozzle bolt...
Page 94 TIGHTENING TORQUES Timing chain cover bolt 1. Tighten the bolts to 6 Nm (0.6 m·kgf, 4.3 ft·lbf) with a torque wrench following the tightening order. 2. Perform the following procedure to all the bolts one by one in the tightening sequence as shown in the illustration.
Page 95 TIGHTENING TORQUES Oil pan bolt 1. Tighten the bolts to 6 Nm (0.6 m·kgf, 4.3 ft·lbf) with a torque wrench following the tightening order. 2. Perform the following procedure to all the bolts one by one in the tightening sequence as shown in the illustration.
Page 96 TIGHTENING TORQUES 2. Perform the following procedure to all the bolts one by one in the tightening sequence as shown in the illustration. a. Loosen the bolt. b. Tighten the bolt to 3.0 Nm (0.30 m·kgf, 2.2 ft·lbf) with a torque wrench. c.
Page 97 TIGHTENING TORQUES EAS30017 CHASSIS TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Rear brake master cylinder lock nut 16 Nm (1.6 m·kgf, 12 ft·lbf) Front brake master cylinder bleed 5 Nm (0.5 m·kgf, 3.6 ft·lbf) screw Brake caliper bleed screw 5 Nm (0.5 m·kgf, 3.6 ft·lbf) Rear wheel axle nut 190 Nm (19 m·kgf, 137 ft·lbf)
Page 98 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Rear brake pad retaining bolt 17 Nm (1.7 m·kgf, 12 ft·lbf) Rear brake caliper screw plug 2.5 Nm (0.25 m·kgf, 1.8 ft·lbf) Rear brake hose union bolt 32 Nm (3.2 m·kgf, 23 ft·lbf) Hydraulic unit assembly nut 8 Nm (0.8 m·kgf, 5.8 ft·lbf) Hydraulic unit brake pipe flare nut...
Page 99 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Spring preload adjusting ring locknut 25 Nm (2.5 m·kgf, 18 ft·lbf) (for YZF-R1) Spring preload adjusting ring locknut 25 Nm (2.5 m·kgf, 18 ft·lbf) (for YZF-R1M) Lower ring nut See TIP. Battery bolt 1.5 Nm (0.15 m·kgf, 1.1 ft·lbf) Rider seat bolt...
Page 100 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Surge tank screw 1.5 Nm (0.15 m·kgf, 1.1 ft·lbf) Intake solenoid screw 1.5 Nm (0.15 m·kgf, 1.1 ft·lbf) Reflector nut (for AUS (2CR6, 2KS6) 3.8 Nm (0.38 m·kgf, 2.8 ft·lbf) /RUS) Front wheel sensor lead holder bolt 7 Nm (0.7 m·kgf, 5.1 ft·lbf) (for YZF-R1)
Page 101 TIGHTENING TORQUES Lower ring nut 1. Tighten the ring nut to 52 Nm (5.2 m·kgf, 38 ft·lbf) with a torque wrench, then loosen the lower ring nut completely. 2. Tighten the lower ring nut to 14 Nm (1.4 m·kgf, 10 ft·lbf). Front wheel axle pinch bolt 1.
Page 102 LUBRICATION POINTS AND LUBRICANT TYPES EAS20018 LUBRICATION POINTS AND LUBRICANT TYPES EAS30018 ENGINE Lubrication point Lubricant Oil seal lips O-rings Water or Coolant hose insertion part Bearings Rocker arm shaft outer surface Camshaft lobes and journals (intake and exhaust) Valve stem seal (installed on valve guide) Valve pad Valve stems and stem ends (intake and exhaust) Crankshaft big ends...
Page 103 Drive sprocket nut and washer Shift drum assembly Shift forks and shift fork guide bars Shift shaft washer Shift shaft moving surface Yamaha bond No. 1215 Crankcase mating surface (Three bond No. 1215®) Yamaha bond No. 1215 Stator coil assembly lead grommet (Three bond No.
Page 104 LUBRICATION POINTS AND LUBRICANT TYPES Lubrication point Lubricant Front wheel axle nut mating surface Rear wheel oil seal Rear wheel drive hub oil seal Rear wheel drive hub mating surface Rear wheel drive hub and rear wheel mating surfaces IMU washer (grommet side) Brake caliper piston seal Master cylinder inside Brake caliper piston dust seal...
Page 105 LUBRICATION POINTS AND LUBRICANT TYPES 2-30...
Page 106 LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20019 LUBRICATION SYSTEM CHART AND DIAGRAMS EAS30020 ENGINE OIL LUBRICATION CHART 2-31...
Page 107 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil strainer 2. Oil pump 3. Relief valve 4. Oil cooler 5. Oil filter cartridge 6. Main gallery 7. Oil pressure switch 8. Crankshaft 9. Generator rotor 10.Balancer shaft 11.Oil nozzle 12.Sub gallery 13.Timing chain tensioner 14.Intake rocker arm 15.Intake camshaft 16.Exhaust rocker arm...
Page 108 LUBRICATION SYSTEM CHART AND DIAGRAMS EAS30021 LUBRICATION DIAGRAMS Crankcase, cylinder, and cylinder head (left side view) 2-33...
Page 109 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Intake camshaft 2. Oil nozzle 3. Oil delivery pipe 2 4. Oil filter cartridge 5. Crankshaft 6. Exhaust camshaft 7. Sub gallery 2-34...
Page 110 LUBRICATION SYSTEM CHART AND DIAGRAMS Crankcase and cylinder (right side view) 2-35...
Page 111 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Timing chain tensioner 2. Intake camshaft 3. Exhaust camshaft 4. Crankshaft 5. Relief valve 6. Oil pipe 1 7. Oil delivery pipe 1 8. Oil pan 9. Oil strainer 10.Oil pump 11.Shift fork guide bar 12.Shift fork-C 13.Drive axle 2-36...
Page 112 LUBRICATION SYSTEM CHART AND DIAGRAMS Timing chain cover and oil pipe (right side view) 2-37...
Page 113 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Timing chain cover 2. Oil pipe 3 3. Oil pipe 2 4. Crankshaft 5. Crankcase 2-38...
Page 114 LUBRICATION SYSTEM CHART AND DIAGRAMS Oil pump and oil cooler (bottom view) 2-39...
Page 115 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil cooler 2. Oil delivery pipe 1 3. Oil cooler outlet hose 4. Oil filter cartridge 5. Oil pressure switch 6. Oil delivery pipe 2 7. Oil strainer 8. Oil pump 9. Oil pipe 1 10.Main gallery 11.Relief valve 12.Oil pipe 2...
Page 116 LUBRICATION SYSTEM CHART AND DIAGRAMS Camshaft and balancer shaft (top view) 2-41...
Page 117 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Cylinder head 2. Exhaust camshaft 3. Intake camshaft 4. Balancer shaft 2-42...
Page 118 LUBRICATION SYSTEM CHART AND DIAGRAMS Crankshaft (rear view) 2-43...
Page 119 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil nozzle 2. Oil pipe 3 3. Timing chain cover 4. Crankshaft 5. Oil pipe 2 6. Oil pressure switch 7. Generator rotor 8. Shaft 2-44...
Page 120 LUBRICATION SYSTEM CHART AND DIAGRAMS Crankshaft and transmission (top view) 2-45...
Page 121 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil pump 2. Main axle 3. Clutch housing 4. Drive axle 5. Oil delivery pipe 3 2-46...
Page 122: Cooling System Diagrams
COOLING SYSTEM DIAGRAMS EAS20020 COOLING SYSTEM DIAGRAMS 2-47...
Page 123 COOLING SYSTEM DIAGRAMS 1. Radiator outlet hose 2. Cooling system air bleed hose 3. Thermostat assembly 4. Radiator inlet hose 5. Radiator 6. Water pump outlet pipe 7. Water pump 8. Water pump inlet pipe 2-48...
Page 124 COOLING SYSTEM DIAGRAMS 2-49...
Page 125 COOLING SYSTEM DIAGRAMS 1. Cooling system air bleed hose 2. Radiator 3. Radiator outlet hose 4. Radiator inlet hose 5. Water pump inlet pipe 6. Water pump outlet pipe 7. Water pump 8. Thermostat assembly 2-50...
Page 126: Cable Routing
CABLE ROUTING EAS20021 CABLE ROUTING Handlebar (front view) 2-51...
Page 127 CABLE ROUTING 1. Clutch cable 2. Immobilizer unit lead 3. Intake solenoid vacuum hose 4. Horn 5. Steering damper solenoid lead 6. Front brake hose 7. Throttle cable (decelerator cable) 8. Throttle cable (accelerator cable) 9. Left handlebar switch lead 10.Main switch lead 11.Right handlebar switch lead 12.Front fork stepping motor sub-lead (right)
Page 128 CABLE ROUTING Clutch cable (right side view) 2-53...
Page 129 CABLE ROUTING 1. Throttle cable (accelerator cable) 2. Throttle cable (decelerator cable) 3. Clutch cable 4. Front brake hose 5. Steering damper solenoid lead 6. Clamp 7. Coolant reservoir breather hose 8. Plastic locking tie 9. Radiator stay 10.Damper 11.Radiator bracket A.
Page 130 CABLE ROUTING sensor lead (right side view) 2-55...
Page 131 CABLE ROUTING 1. O sensor lead 2. Rear wheel sensor lead 3. Rear brake light switch lead 4. EXUP cable A. Push in the O sensor lead from the outside until it reaches the alignment surface of the clutch cover. B.
Page 132 CABLE ROUTING Electrical components tray (left side view) 2-57...
Page 133 CABLE ROUTING I. When installing the plastic locking tie to the 1. Intake funnel servo motor lead electrical components tray, position it in the 2. Right handlebar switch lead (non-waterproof center within the range shown in the illustra- 2-pole) tion. 3.
Page 134 CABLE ROUTING ECU (Engine Control Unit) (left side view) 2-59...
Page 135 CABLE ROUTING K. The sidestand switch lead, O sensor lead, 1. Secondary injector lead oil pressure switch lead and shift switch lead 2. Throttle position sensor coupler may be routed in any order. 3. ECU (engine control unit) coupler L. Fasten the sidestand switch lead, O sensor 4.
Page 136 CABLE ROUTING Frame (top view) 2-61...
Page 137 CABLE ROUTING 1. Steering damper solenoid lead 2. Intake solenoid lead (sub-wire harness) 3. Front turn signal light lead (right) 4. Meter assembly 5. Intake air temperature sensor lead 6. Intake solenoid vacuum hose 7. Auxiliary light lead 8. Front turn signal light lead (left) 9.
Page 138 CABLE ROUTING Frame (top view) (for YZF-R1M) 2-63...
Page 139 CABLE ROUTING 1. Steering damper solenoid coupler (OHLINS: OPTION) 2. SCU lead (sub-wire harness) 3. Intake air temperature sensor 4. Sub-wire harness (SCU, steering damper solenoid, sub-wire harness) 5. Auxiliary light lead 6. Sub-wire harness (front fork stepping motor) 7. Plastic locking tie 8.
Page 140 CABLE ROUTING Frame (top view) 2-65...
Page 141 CABLE ROUTING H. Fasten the leads (right handlebar switch lead 1. Horn lead (blue), left handlebar switch lead (gray), main 2. Main switch lead switch lead (white), sub-wire harness (for 3. Left handlebar switch lead YZF-R1M) (white)) at the positioning tape on 4.
Page 142 CABLE ROUTING Frame (top view) 2-67...
Page 143 CABLE ROUTING 1. Coolant temperature sensor coupler 2. Primary injector #4 3. Primary injector #3 4. Plastic locking tie 5. O sensor lead 6. Neutral switch lead 7. Fuel pump lead 8. Engine ground lead 9. Starter motor lead 10.Primary injector #2 11.Primary injector #1 12.Frame 13.Round terminal...
Page 144 CABLE ROUTING Rear fender (top view) 2-69...
Page 145 I. Route the negative battery lead through the 1. Rear wheel sensor coupler inside of the rib. 2. Rear brake light switch coupler J. Insert the Yamaha diagnostic tool coupler 3. Hydraulic unit until it contacts the battery box as shown in 4. Battery the illustration.
Page 146 CABLE ROUTING Rear fender (left side view) 2-71...
Page 147 CABLE ROUTING 1. Rider seat 2. Passenger seat 3. Tail/brake light 4. Mudguard assembly 5. License plate light coupler 6. Rear turn signal light coupler 7. Passenger footrest 8. Rear turn signal light lead 9. Tail/brake light bracket 10.EXUP cable 1 11.EXUP cable 2 12.Battery box A.
Page 148 CABLE ROUTING Rear brake hose (right side view) 2-73...
Page 149 CABLE ROUTING L. Install the grommet of the rear wheel sensor 1. Hydraulic unit lead securely to the rear wheel sensor pro- 2. Rear frame tector. 3. Brake fluid reservoir When installing the grommet on the rear 4. Frame wheel sensor lead, may apply silicone fluid or soapy water to the grommet.
Page 150 CABLE ROUTING Front brake hose (left side view) 2-75...
Page 151 CABLE ROUTING 1. Brake hose (front brake master cylinder to hydraulic unit) 2. Clamp 3. Brake hose (hydraulic unit to front brake cali- pers) 4. Front wheel sensor lead 5. Front brake caliper 6. Front wheel sensor 7. Front fork 8.
Page 152 CABLE ROUTING Front brake hose (left side view) 2-77...
Page 153 CABLE ROUTING 1. Brake hose bracket 2. Clamp 3. Frame 4. Brake hose (hydraulic unit to front brake cali- pers) 5. Brake hose (front brake master cylinder to hydraulic unit) A. Install the brake hose (front brake master cyl- inder to the hydraulic unit) so that it is on the inside relative to the brake hose (hydraulic unit to the front brake caliper).
Page 154 CABLE ROUTING Hydraulic unit assembly (top and left side view) 2-79...
Page 155 CABLE ROUTING 1. Brake hose (front brake master cylinder to hydraulic unit) 2. Brake hose (hydraulic unit to front brake cali- pers) 3. Hydraulic unit brake pipe (hydraulic unit to front brake calipers) 4. Hydraulic unit brake pipe (front brake master cylinder to hydraulic unit) 5.
Page 156 CABLE ROUTING Fuel tank (top and left side view) 2-81...
Page 157 CABLE ROUTING 1. Fuel tank 2. Fuel pump 3. Fuel tank breather hose 4. Fuel tank drain hose 5. Fuel hose (fuel tank to fuel rail) A. Point the end of the clamp outward. B. Install the fuel tank drain hose with its white paint mark facing outward.
Page 158 CABLE ROUTING Air filter case and throttle bodies (top and left side view) 2-83...
Page 159 CABLE ROUTING 1. Air filter case 2. Secondary injector 3. Fuel hose (fuel rail to fuel rail) 4. Crankcase breather hose 5. Primary injector 6. Throttle body assembly 7. Intake solenoid vacuum hose (throttle body to one-way valve) 8. Throttle cable (accelerator cable) 9.
Page 160 CABLE ROUTING Air cut-off valve (right side view) 2-85...
Page 161 CABLE ROUTING 1. Air filter case 2. Air cut-off valve 3. Air induction system hose (air filter case to air cut-off valve) 4. Cylinder head cover 5. Air induction system hose (air cut-off valve to reed valve cover) 6. Cylinder identification sensor 7.
Page 162 CABLE ROUTING Air duct (left and right side view) 2-87...
Page 163 CABLE ROUTING 1. Air intake duct valve 2. Air intake duct 3. Intake air temperature sensor 4. Surge tank 5. Surge tank hose 6. One-way valve 7. Intake solenoid vacuum hose (one-way valve to intake solenoid) 8. Intake solenoid vacuum hose (intake sole- noid to air intake duct valve) 9.
Page 164 CABLE ROUTING Radiator (left side view) 2-89...
Page 165 CABLE ROUTING S. Face the opening of the hose clamp to the 1. Cooling system air bleed hose left. 2. Clamp 3. Thermostat assembly 4. Hose clamp 5. Radiator inlet hose 6. Cylinder 7. Crankcase 8. Generator cover 9. Water pump outlet pipe 10.Radiator outlet hose A.
Page 166 CABLE ROUTING Radiator (right side view) 2-91...
Page 167 CABLE ROUTING 1. Cooling system air bleed hose 2. Clamp 3. Radiator outlet hose 4. Hose clamp 5. Water pump inlet pipe 6. Water pump outlet pipe 7. Thermostat assembly A. Route the cooling system air bleed hose out- side to the air induction system hose. B.
Page 168 CABLE ROUTING Muffler (top and left side view) 2-93...
Page 169 CABLE ROUTING 1. Exhaust chamber 2. EXUP valve pulley cover 3. Muffler 4. EXUP servo motor 5. EXUP cable 2 6. EXUP cable 1 A. EXUP cable securing location 2-94...
Page 170 CABLE ROUTING CCU (top and right side view) (for YZF-R1M) 2-95...
Page 171 CABLE ROUTING 1. CCU (Communication Control Unit) 2. GPS unit lead 3. GPS unit coupler 4. Yamaha diagnostic tool coupler (wire har- ness) 5. Yamaha diagnostic tool coupler (sub-wire harness) 6. Sub-wire harness 7. Passenger seat cover 8. GPS unit 9.
Page 172 CABLE ROUTING 2-97...
Page 173 PERIODIC CHECKS AND ADJUSTMENTS PERIODIC MAINTENANCE ................3-1 INTRODUCTION ..................3-1 PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM ....................3-1 GENERAL MAINTENANCE AND LUBRICATION CHART ......3-1 CHECKING THE FUEL LINE (Primary injector).........3-4 CHECKING THE FUEL LINE (Secondary injector) ........3-4 CHECKING THE SPARK PLUGS ..............3-4 ADJUSTING THE VALVE CLEARANCE ...........3-5 CHECKING THE ENGINE IDLING SPEED ..........3-9 SYNCHRONIZING THE THROTTLE BODIES...........3-9...
Page 174 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY ....3-26 ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY (for YZF-R1) ....................3-26 ADJUSTING THE PRELOAD OF THE REAR SHOCK ABSORBER ASSEMBLY (for YZF-R1M) ..............3-28 CHECKING THE CONNECTING ARM AND RELAY ARM......3-29 CHECKING THE ENGINE OIL LEVEL.............3-29 CHANGING THE ENGINE OIL ..............3-30 MEASURING THE ENGINE OIL PRESSURE .........3-31 CHECKING THE COOLANT LEVEL............3-32...
Page 175 UK, a mileage-based maintenance, is performed instead. • From 50000 km (30000 mi), repeat the maintenance intervals starting from 10000 km (6000 mi). • Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills.
Page 176 PERIODIC MAINTENANCE ODOMETER READING CHECK OR MAINTENANCE ANNUAL ITEM CHECK 1000 km 10000 km 20000 km 30000 km 40000 km (600 mi) (6000 mi) (12000 mi) (18000 mi) (24000 mi) • Check for cracks or damage. • Check for correct routing and 5 * Brake hoses clamping.
Page 177 PERIODIC MAINTENANCE ODOMETER READING CHECK OR MAINTENANCE ANNUAL ITEM CHECK 1000 km 10000 km 20000 km 30000 km 40000 km (600 mi) (6000 mi) (12000 mi) (18000 mi) (24000 mi) Engine oil filter • Replace. cartridge • Check coolant level and vehi- cle for coolant leakage.
Page 178 PERIODIC MAINTENANCE 4-1. EAS30619 CHECKING THE FUEL LINE (Primary • Fuel tank cover injector) Refer to “GENERAL CHASSIS (2)” on page The following procedure applies to all of the fuel, 4-7. drain and breather hoses. • Fuel tank 1. Remove: Refer to “FUEL TANK”...
Page 179 PERIODIC MAINTENANCE • Spark plugs Nm (1.8 m·kgf, 13 ft·lbf). ECA13320 8. Install: NOTICE • Air cut-off valve Before removing the spark plugs, blow away Refer to “AIR INDUCTION SYSTEM” on any dirt accumulated in the spark plug wells page 7-19. with compressed air to prevent it from falling •...
Page 180 PERIODIC MAINTENANCE 4. Measure: • Valve clearance Out of specification Adjust. Valve clearance (cold) Intake 0.09–0.17 mm (0.0035–0.0067 in) Exhaust 0.18–0.23 mm (0.0071–0.0091 in) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Turn the crankshaft counterclockwise. • If the valve clearance is incorrect, record the b. When piston #1 is at TDC on the compres- measured reading.
Page 181 PERIODIC MAINTENANCE f. Measure the valve clearance #3 with a thick- l. Measure the valve clearance #4 with a thick- ness gauge. ness gauge. Thickness gauge Thickness gauge 90890-03180 90890-03180 Feeler gauge set Feeler gauge set YU-26900-9 YU-26900-9 g. Turn the crankshaft counterclockwise. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲...
Page 182 PERIODIC MAINTENANCE e. Round off the valve pad number according to the following table, and then select the suit- able valve pad. Last digit Rounded value 0, 1, 2 3, 4, 5, 6 7, 8, 9 Refer to the following table for the available b.
Page 183 Refer to “CHECKING AND CLEANING THE THROTTLE BODIES” on page 7-12. Vacuum gauge 90890-03094 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ Vacuummate a. Connect the Yamaha diagnostic tool. YU-44456 Use the diagnostic code number “67”. Refer to “SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE (ECU)” on page 9-5.
Page 184 PERIODIC MAINTENANCE at idle and the throttle bodies may not oper- ate properly. • Turn the bypass air screw using the carburetor angle driver. • After each step, rev the engine two or three times, each time for less than a second, and check the synchronization again.
Page 185 PERIODIC MAINTENANCE Throttle grip free play 3.0–5.0 mm (0.12–0.20 in) EAS31318 CHECKING THE THROTTLE BODY JOINTS 1. Remove: • Throttle bodies Refer to “THROTTLE BODIES” on page 7-9. 2. Check: • Throttle body joints “1” Cracks/damage Replace. 3. Install: • Fuel tank Refer to “FUEL TANK”...
Page 186 Yamaha diagnostic tool. For more information, refer to the opera- tion manual of the Yamaha diagnostic tool. 1. Connect the Yamaha diagnostic tool to the coupler. For information about connecting the Yamaha diagnostic tool, refer to “YAMAHA 4.
Page 187 PERIODIC MAINTENANCE 5. Install: • Fuel tank If the specified clutch lever free play cannot be Refer to “FUEL TANK” on page 7-1. obtained on the handlebar side of the cable, use • Fuel tank cover the adjusting nut on the engine side. Refer to “GENERAL CHASSIS (2)”...
Page 188 PERIODIC MAINTENANCE EAS30801 EWA13090 CHECKING THE BRAKE OPERATION WARNING 1. Check: • Use only the designated brake fluid. Other • Brake operation brake fluids may cause the rubber seals to Brake not working properly Check the deteriorate, causing leakage and poor brake system.
Page 189 PERIODIC MAINTENANCE EWA17050 Direction “a” WARNING Brake pedal is raised. • After adjusting the brake lever position, Direction “b” make sure the pin on the brake lever holder Brake pedal is lowered. is firmly inserted in the hole in the adjusting dial.
Page 190 PERIODIC MAINTENANCE Refer to “REAR BRAKE” on page 4-55. EAS30893 BLEEDING THE HYDRAULIC BRAKE SYSTEM (ABS) EWA14000 WARNING Always bleed the brake system when the brake related parts are removed. ECA22640 NOTICE • Bleed the brake system in the following or- der.
Page 191 PERIODIC MAINTENANCE ECA17061 NOTICE Make sure that the main switch is turned to “OFF” before checking the operation of the hydraulic unit. k. After operating the ABS, repeat steps (e) to (i), and then fill the brake fluid reservoir to the proper level with the specified brake fluid.
Page 192 290 kPa (2.90 kgf/cm², 42 psi) cerning handling characteristics can be giv- Loading condition en if a tire combination other than one 90–188 kg (198–414 lb) approved by Yamaha is used on this vehicle. Front 250 kPa (2.50 kgf/cm², 36 psi) Front tire Rear Size 290 kPa (2.90 kgf/cm², 42 psi)
Page 193 PERIODIC MAINTENANCE 2. Check: Rear tire • Swingarm excessive play Size Refer to “SWINGARM” on page 4-112. YZF-R1 190/55 ZR17M/C (75W) YZF-R1M 200/55 ZR17M/C (78W) EAS30643 LUBRICATING THE SWINGARM PIVOT Manufacturer/model YZF-R1 1. Lubricate: BRIDGESTONE/BATTLAX RAC- • Oil seals ING STREET RS10R G or PIREL- •...
Page 194 PERIODIC MAINTENANCE Drive chain slack • To maintain the proper wheel alignment, adjust 25.0–35.0 mm (0.98–1.38 in) both sides evenly. • There should be no clearance between the ad- ECA20870 justing block and adjusting bolt. NOTICE Improper drive chain slack will overload the c.
Page 195 PERIODIC MAINTENANCE EAS30645 CHECKING AND ADJUSTING THE STEERING HEAD 1. Stand the vehicle on a level surface. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. Place the vehicle on a suitable stand so that the front wheel is elevated.
Page 196 PERIODIC MAINTENANCE Recommended lubricant Lithium-soap-based grease EAS30650 CHECKING THE SIDESTAND 1. Check: • Sidestand operation Check that the sidestand moves smoothly. Rough movement Repair or replace. EAS30651 LUBRICATING THE SIDESTAND ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ Lubricate the pivoting point, metal-to-metal mov- 5. Install: ing parts and spring contact point of the sides- •...
Page 197 PERIODIC MAINTENANCE ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS30806 ADJUSTING THE FRONT FORK LEGS (for Rebound damping YZF-R1) ECA13590 The following procedure applies to both of the NOTICE front fork legs. Never go beyond the maximum or minimum EWA13120 adjustment positions. WARNING 1. Adjust: Securely support the vehicle so that there is •...
Page 198 PERIODIC MAINTENANCE ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ Compression damping EAS31635 ECA13590 ADJUSTING THE PRELOAD OF THE FRONT NOTICE FORK LEGS (for YZF-R1M) Never go beyond the maximum or minimum The following procedure applies to both of the adjustment positions. front fork legs. 1. Adjust: EWA13120 WARNING •...
Page 199 PERIODIC MAINTENANCE 1. Adjust: Direction “a” • Damping force Spring preload is increased (suspen- sion is harder). ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Turn the main switch to “ON”. Direction “b” b. Long push the wheel switch to enter the Spring preload is decreased (suspen- sion is softer).
Page 200 PERIODIC MAINTENANCE YRC Setting 12:00 km/h YRC Setting 12:00 km/h A - 2 A - 2 A - 3 A - 3 M - 1 M - 1 M - 2 M - 2 M - 3 M - 3 SETTING Fr COM Fr REB...
Page 201 PERIODIC MAINTENANCE Direction “a” Rebound damping is increased (sus- pension is harder). Direction “b” Rebound damping is decreased (sus- pension is softer). Rebound damping adjusting posi- tions Minimum (soft) 23 click(s) in direction “b” Standard The spring preload setting is determined by 12 click(s) in direction “b”...
Page 202 PERIODIC MAINTENANCE Direction “a” Direction “a” Compression damping is increased Compression damping is increased (suspension is harder). (suspension is harder). Direction “b” Direction “b” Compression damping is decreased Compression damping is decreased (suspension is softer). (suspension is softer). Compression damping setting (for Compression damping setting (for fast compression damping) slow compression damping)
Page 203 PERIODIC MAINTENANCE ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Loosen the locknut “1”. b. Adjust the spring preload with the special EAS30809 CHECKING THE CONNECTING ARM AND wrench included in the owner’s tool kit. RELAY ARM c. Turn the adjusting ring “2” in direction “a” or Refer to “CHECKING THE CONNECTING ARM “b”.
Page 204 PERIODIC MAINTENANCE Oil filter wrench Before checking the engine oil level, wait a few 90890-01426 minutes until the oil has settled. Oil filter wrench YU-38411 4. Start the engine, warm it up for several min- utes, and then turn it off. 5.
Page 205 PERIODIC MAINTENANCE • Oil pressure switch joint (with the oil pressure mended engine oil) switch) “2” Engine oil quantity EWA12980 Quantity (disassembled) WARNING 4.90 L (5.18 US qt, 4.31 Imp.qt) The engine, muffler and engine oil are ex- Without oil filter cartridge re- tremely hot.
Page 206 PERIODIC MAINTENANCE EAS30811 CHECKING THE COOLANT LEVEL 1. Stand the vehicle on a level surface. • Place the vehicle on a suitable stand. • Make sure the vehicle is upright. 2. Check: • Coolant level The coolant level should be between the maximum level mark “a”...
Page 207 PERIODIC MAINTENANCE Cracks/damage Replace. Refer to “RADIATOR” on page 6-1, “OIL COOLER” on page 6-4, “THERMOSTAT” on page 6-6 and “WATER PUMP” on page 6-9. 2. Remove: • Water pump drain bolt “1” • Copper washer “2” 3. Drain: EAS30813 •...
Page 208 PERIODIC MAINTENANCE antifreeze concentration of the coolant. If water is used instead of coolant; check, and if necessary, correct the antifreeze concentration of the coolant. • Use only distilled water. However, if dis- tilled water is not available, soft water may be used.
Page 209 PERIODIC MAINTENANCE utes, and then turn it off. 17.Check: • Coolant level Refer to “CHECKING THE COOLANT LEV- EL” on page 3-32. Before checking the coolant level, wait a few minutes until the coolant has settled. 18.Install: • Front muffler protector (right) •...
Page 210 PERIODIC MAINTENANCE g. Tighten the locknut “4” to specification. EXUP cable locknut 6 Nm (0.6 m·kgf, 4.3 ft·lbf) ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS31147 CHECKING AND LUBRICATING THE CABLES The following procedure applies to all of the in- ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ ner and outer cables. 4. Install: •...
Page 211 PERIODIC MAINTENANCE Recommended lubricant Suitable cable lubricant With the engine stopped, turn the throttle grip slowly and release it. Make sure that the throttle grip turns smoothly and returns properly when released. Repeat this check with the handlebar turned all the way to the left and right.
Page 212 PERIODIC MAINTENANCE pletely by the rubber cover. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS30816 CHECKING AND CHARGING THE BATTERY Refer to “CHECKING AND CHARGING THE BATTERY” on page 8-181. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS30662 CHECKING THE FUSES 2. Adjust: Refer to “CHECKING THE FUSES” on page • Headlight beam (horizontally) 8-180.
Page 213 PERIODIC MAINTENANCE ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 3-39...
Page 214 PERIODIC MAINTENANCE 3-40...
Page 215 CHASSIS GENERAL CHASSIS (1) ..................4-1 INSTALLING THE IMU................4-5 CONNECTING TO THE CCU (for YZF-R1M) ..........4-5 GENERAL CHASSIS (2) ..................4-7 REMOVING THE FRONT SIDE COWLINGS (for YZF-R1) .....4-13 REMOVING THE FRONT SIDE COWLINGS (for YZF-R1M) ....4-13 INSTALLING THE FRONT SIDE COWLINGS (for YZF-R1)....4-13 INSTALLING THE FRONT SIDE COWLINGS (for YZF-R1M)....4-14 REMOVING THE FRONT PANELS ............4-14 INSTALLING THE FRONT PANELS............4-14...
Page 216 CHECKING THE FRONT BRAKE DISCS..........4-48 REPLACING THE FRONT BRAKE PADS ..........4-49 REMOVING THE FRONT BRAKE CALIPERS ........4-50 DISASSEMBLING THE FRONT BRAKE CALIPERS.......4-51 CHECKING THE FRONT BRAKE CALIPERS .........4-51 ASSEMBLING THE FRONT BRAKE CALIPERS........4-51 INSTALLING THE FRONT BRAKE CALIPERS ........4-52 REMOVING THE FRONT BRAKE MASTER CYLINDER ......4-53 CHECKING THE FRONT BRAKE MASTER CYLINDER......4-53 ASSEMBLING THE FRONT BRAKE MASTER CYLINDER ....4-53 INSTALLING THE FRONT BRAKE MASTER CYLINDER.......4-53...
Page 217 CHECKING THE FRONT FORK LEGS (for YZF-R1M) ......4-93 ASSEMBLING THE FRONT FORK LEGS (for YZF-R1M).......4-94 INSTALLING THE FRONT FORK LEGS (for YZF-R1M) ......4-97 STEERING HEAD..................4-100 REMOVING THE LOWER BRACKET............4-102 CHECKING THE STEERING HEAD ............4-102 INSTALLING THE STEERING HEAD ............4-103 CHECKING THE STEERING DAMPER..........4-103 REAR SHOCK ABSORBER ASSEMBLY............4-104 HANDLING THE REAR SHOCK ABSORBER ........4-108 DISPOSING OF A REAR SHOCK ABSORBER ........4-108...
Page 218 GENERAL CHASSIS (1) EAS20026 GENERAL CHASSIS (1) Removing the seats and battery 1.5 Nm (0.15 m kgf, 1.1 ft lbf) 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) •...
Page 219 GENERAL CHASSIS (1) Removing the rear side covers and rear fender 7 Nm (0.7 m kgf, 5.1 ft lbf) 7 Nm (0.7 m kgf, 5.1 ft lbf) • • • • 9 Nm (0.9 m kgf, 6.5 ft lbf) • •...
Page 220 GENERAL CHASSIS (1) Disassembling the mudguard assembly 3.8 Nm (0.38 m kgf, 2.8 ft lbf) • • Order Job/Parts to remove Q’ty Remarks Mudguard assembly cover Clamp Stay Rear turn signal light Cover License plate light Rear reflector...
Page 221 Refer to “GENERAL CHASSIS (1)” on page cover 4-1. Passenger seat cover GPS unit coupler Disconnect. Cushion GPS unit CCU coupler (sub-wire harness) Disconnect. Band CCU (Communication Control Unit) CCU bracket 1 CCU bracket 2 Yamaha diagnostic tool coupler (wire harness) Disconnect. Protective cap Sub-wire harness...
Page 222 GENERAL CHASSIS (1) EAS31636 INSTALLING THE IMU ECA22611 NOTICE • Do not perform angle adjustment of the IMU and battery box by pinching the washer and related parts. • When installing the IMU, apply a thin coat of silicone grease onto the washer where con- tacting the IMU grommet.
Page 223 Turn the main switch to “ON” and approach the vehicle with a wireless capable smart- phone, tablet, or laptop computer. d. Connect to the wireless network “Yamaha Motor Network” by inputting the CCU serial number as the password. Since all CCU-equipped models put out a simi- larly named wireless network, have only one ve- hicle turned on at a time to avoid confusion.
Page 224 GENERAL CHASSIS (2) EAS20155 GENERAL CHASSIS (2) Removing the fuel tank covers 5 Nm (0.5 m kgf, 3.6 ft lbf) • • 0.4 Nm (0.04 m kgf, 0.29 ft lbf) • • 4.0 Nm (0.40 m kgf, 2.9 ft lbf) •...
Page 225 GENERAL CHASSIS (2) Removing the front side cowlings (for YZF-R1) 9 Nm (0.9 m kgf, 6.5 ft lbf) 9 Nm (0.9 m kgf, 6.5 ft lbf) • • • • 9 Nm (0.9 m kgf, 6.5 ft lbf) • • 9 Nm (0.9 m kgf, 6.5 ft lbf)
Page 226 GENERAL CHASSIS (2) Removing the front side cowlings (for YZF-R1M) 9 Nm (0.9 m kgf, 6.5 ft lbf) 9 Nm (0.9 m kgf, 6.5 ft lbf) • • • • 9 Nm (0.9 m kgf, 6.5 ft lbf) • • 9 Nm (0.9 m kgf, 6.5 ft lbf)
Page 227 GENERAL CHASSIS (2) Removing the front panel (left) and side cover (left) 1.8 Nm (0.18 m kgf, 1.3 ft lbf) • • 3.0 Nm (0.30 m kgf, 2.2 ft lbf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) •...
Page 228 GENERAL CHASSIS (2) Removing the front panel (right) and side cover (right) 3.5 Nm (0.35 m kgf, 2.5 ft lbf) • • 1.8 Nm (0.18 m kgf, 1.3 ft lbf) • • 3.5 Nm (0.35 m kgf, 2.5 ft lbf) •...
Page 229 GENERAL CHASSIS (2) Removing the electrical components tray 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Front side cowling (left)/Front panel (left)/Side Refer to “GENERAL CHASSIS (2)”...
Page 230 GENERAL CHASSIS (2) EAS31381 REMOVING THE FRONT SIDE COWLINGS (for YZF-R1) 1. Remove: • Front side cowling (left) “1” ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the quick fastener screws “2” and the quick fasteners “3”. b. Remove the left front side cowling by pulling it forward.
Page 231 GENERAL CHASSIS (2) 2. Install: Front side cowling bolt (for • Front side cowling (left) “1” YZF-R1M) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ 9 Nm (0.9 m·kgf, 6.5 ft·lbf) a. Install the left front side cowling. b. Install the quick fastener screws “2” and the quick fasteners “3”.
Page 232 GENERAL CHASSIS (2) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Install the front panel. Insert projection on the front panel into grommet. b. Install the quick fastener “3” and bolt “4”, and then tighten the bolt to specification. Front panel bolt (left) 3.0 Nm (0.30 m·kgf, 2.2 ft·lbf) Front panel bolt (right) 3.5 Nm (0.35 m·kgf, 2.5 ft·lbf) ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲...
Page 233 GENERAL CHASSIS (2) EAS31641 REMOVING THE ECU (Engine Control Unit) 1. Disconnect: • ECU coupler “1” While pushing the portion “a” of the ECU cou- pler, move the lock lever “b” in the direction of the arrow shown to disconnect the coupler. EAS31642 INSTALLING THE ECU (Engine Control Unit) 1.
Page 234 GENERAL CHASSIS (3) EAS20156 GENERAL CHASSIS (3) Removing the Rearview mirrors and windshield 0.4 Nm (0.04 m kgf, 0.29 ft lbf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) 4.0 Nm (0.40 m kgf, 2.9 ft lbf) • •...
Page 235 GENERAL CHASSIS (3) Removing the front cowling assembly 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS (2)” on page Front side cowling/Headlight cover/Front panel 4-7.
Page 236 GENERAL CHASSIS (3) Disassembling the front cowling assembly 1.5 Nm (0.15 m kgf, 1.1 ft lbf) • • 4.3 Nm (0.43 m kgf, 3.1 ft lbf) • • 1.5 Nm (0.15 m kgf, 1.1 ft lbf) • • 1.5 Nm (0.15 m kgf, 1.1 ft lbf) •...
Page 237 GENERAL CHASSIS (3) Removing the air intake duct 1.5 Nm (0.15 m kgf, 1.1 ft lbf) • • 11 Nm (1.1 m kgf, 8.0 ft lbf) • • 11 Nm (1.1 m kgf, 8.0 ft lbf) • • 1.5 Nm (0.15 m kgf, 1.1 ft lbf) •...
Page 238 GENERAL CHASSIS (3) EAS31643 REMOVING THE WINDSHIELD ASSEMBLY 1. Remove: • Front side panel (left) • Front side panel (right) Refer to “GENERAL CHASSIS (2)” on page 4-7. 2. Remove: • Windshield assembly ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Disconnect the turn signal light couplers “1”. d.
Page 239 GENERAL CHASSIS (3) 2. Install: Windshield assembly bolt • Front side panel (left) 4.0 Nm (0.40 m·kgf, 2.9 ft·lbf) • Front side panel (right) Refer to “GENERAL CHASSIS (2)” on page 4-7. EAS31645 CHECKING THE AIR INTAKE DUCT VALVE 1. Check: •...
Page 240 GENERAL CHASSIS (3) 4. Check: ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ • Intake solenoid Damage Replace. 5. Check: • Intake solenoid resistance Refer to “CHECKING THE INTAKE SOLE- NOID” on page 8-195. 6. Check: • Surge tank Cracks/damage Replace. EAS31647 INSTALLING THE AIR INTAKE DUCT VALVE 1.
Page 241 FRONT WHEEL EAS20028 FRONT WHEEL Removing the front wheel and brake discs (for YZF-R1) 6 Nm (0.6 m kgf, 4.3 ft Ibf) • • 3.8 Nm (0.38 m kgf, 2.8 ft lbf) • • 6 Nm (0.6 m kgf, 4.3 ft Ibf) •...
Page 242 FRONT WHEEL Removing the front wheel and brake discs (for YZF-R1M) 6 Nm (0.6 m kgf, 4.3 ft Ibf) • • 3.8 Nm (0.38 m kgf, 2.8 ft lbf) • • 6 Nm (0.6 m kgf, 4.3 ft Ibf) • •...
Page 243 FRONT WHEEL Disassembling the front wheel 8 Nm (0.8 m kgf, 5.8 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Front wheel sensor rotor Oil seal Wheel ring Wheel bearing Spacer 4-26...
Page 244 FRONT WHEEL • If any solvent gets on the wheel sensor ro- EAS30145 REMOVING THE FRONT WHEEL tor, wipe it off immediately. ECA21380 NOTICE 1. Remove: • Oil seals Keep magnets (including magnetic pick-up • Wheel bearings tools, magnetic screwdrivers, etc.) away from the front wheel sensor “1”, otherwise ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼...
Page 245 FRONT WHEEL EAS30151 ASSEMBLING THE FRONT WHEEL ECA21340 NOTICE • Do not drop the wheel sensor rotor or sub- ject it to shocks. • If any solvent gets on the wheel sensor ro- tor, wipe it off immediately. 1. Install: •...
Page 246 FRONT WHEEL • Do not drop or shock the wheel sensor or ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ the wheel sensor rotor. 2. Install: • Front wheel sensor rotor 1. Check: • Front wheel sensor “1” Wheel sensor rotor bolt Cracks/bends/distortion Replace. 8 Nm (0.8 m·kgf, 5.8 ft·lbf) Iron powder/dust Clean.
Page 247 FRONT WHEEL ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Spin the front wheel. b. When the front wheel stops, put an “X ” mark at the bottom of the wheel. c. Turn the front wheel 90 so that the “X ” mark is positioned as shown. d.
Page 248 FRONT WHEEL b. Turn the front wheel 90 so that the heavy spot is positioned as shown. 2. Apply: • Sealant c. If the heavy spot does not stay in that posi- tion, install a heavier weight. Apply Three Bond No. 1215B® onto the corner d.
Page 249 FRONT WHEEL ing surface of the front wheel axle nut. 6. Tighten: • Front wheel axle nut Front wheel axle nut 115 Nm (11.5 m·kgf, 83 ft·lbf) ECA14140 NOTICE Before tightening the wheel axle nut, push down hard on the handlebar(s) several times and check if the front fork rebounds smooth- ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲...
Page 250 FRONT WHEEL Distance “a” (between the front wheel sensor rotor and front wheel sensor) 0.9–1.7 mm (0.035–0.067 in) (for YZF-R1) 1.1–1.9 mm (0.043–0.075 in) (for YZF-R1M) Measure the distance between the front wheel sensor rotor and front wheel sensor in several places in one rotation of the front wheel.
Page 251 REAR WHEEL EAS20029 REAR WHEEL Removing the rear wheel 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 190 Nm (19 m kgf, 137 ft lbf) • • 16 Nm (1.6 m kgf, 12 ft lbf) 16 Nm (1.6 m kgf, 12 ft lbf) •...
Page 252 REAR WHEEL Removing the brake disc and rear wheel sprocket 8 Nm (0.8 m kgf, 5.8 ft Ibf) 30 Nm (3.0 m kgf, 22 ft lbf) • • • • 105 Nm ( 10.5 m kgf, 76 ft lbf) • •...
Page 253 REAR WHEEL Disassembling the rear wheel 80 Nm (8.0 m kgf, 58 ft lbf) • • Order Job/Parts to remove Q’ty Remarks Collar Oil seal Wheel bearing Spacer Oil seal Wheel bearing ring nut Wheel bearing 4-36...
Page 254 REAR WHEEL 2. Remove: EAS30910 REMOVING THE REAR WHEEL • Rear brake caliper “1” ECA21390 • Rear wheel sensor protector “2” NOTICE • Rear wheel sensor “3” Keep magnets (including magnetic pick-up ECA21040 tools, magnetic screwdrivers, etc.) away NOTICE from the rear wheel sensor “1”, otherwise •...
Page 255 REAR WHEEL • Wheel bearings Refer to “DISASSEMBLING THE FRONT WHEEL” on page 4-27. EAS30159 CHECKING THE REAR WHEEL 1. Check: • Wheel axle • Wheel bearings • Oil seals Refer to “CHECKING THE FRONT WHEEL” on page 4-27. EAS30158 DISASSEMBLING THE REAR WHEEL 2.
Page 256 REAR WHEEL • Oil seal Refer to “ASSEMBLING THE FRONT WHEEL” on page 4-28. 2. Install: • Wheel bearing ring nut Apply locking agent (LOCTITE®) onto the two symmetric places on the circumference of the threads of the wheel bearing ring nut. b.
Page 257 REAR WHEEL since they have been accurately adjusted. Keep them away from dirt and do not sub- ject them to shocks. • The rear wheel sensor cannot be disassem- bled. Do not attempt to disassemble it. If faulty, replace with a new one. •...
Page 258 REAR WHEEL ECA19150 NOTICE Replace the brake disc bolts with new ones. Tighten the brake disc bolts in stages and in a crisscross pattern. 5. Install: • Rear brake caliper • Rear brake caliper bolts 6. Adjust: • Drive chain slack Refer to “ADJUSTING THE DRIVE CHAIN SLACK”...
Page 259 REAR WHEEL 8. Install: • Rear wheel sensor • Rear wheel sensor protector Rear wheel sensor bolt 7 Nm (0.7 m·kgf, 5.1 ft·lbf) Rear wheel sensor protector bolt 7 Nm (0.7 m·kgf, 5.1 ft·lbf) ECA21080 NOTICE Make sure there are no foreign materials in the rear wheel sensor rotor and rear wheel sensor.
Page 260 FRONT BRAKE EAS20030 FRONT BRAKE Removing the front brake pads 6 Nm (0.6 m kgf, 4.3 ft Ibf) • • 5 Nm (0.5 m kgf, 3.6 ft Ibf) • • 35 Nm (3.5 m kgf, 25 ft lbf) • • Order Job/Parts to remove Q’ty...
Page 261 FRONT BRAKE Removing the front brake master cylinder 3.5 Nm (0.35 m kgf, 2.5 ft lbf) • • 1.2 Nm (0.12 m kgf, 0.87 ft lbf) • • 32 Nm (3.2 m kgf, 23 ft lbf) • • 1.0 Nm (0.10 m kgf, 0.72 ft lbf) •...
Page 262 FRONT BRAKE Disassembling the front brake master cylinder 5 Nm (0.5 m kgf, 3.6 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Brake master cylinder kit Bleed screw Brake master cylinder body 4-45...
Page 263 FRONT BRAKE Removing the front brake calipers 6 Nm (0.6 m kgf, 4.3 ft Ibf) • • 32 Nm (3.2 m kgf, 23 ft lbf) • • 35 Nm (3.5 m kgf, 25 ft lbf) • • Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of...
Page 264 FRONT BRAKE Disassembling the front brake calipers 5 Nm (0.5 m kgf, 3.6 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of the front brake calipers. Brake pad clip Brake pad pin Brake pad spring Brake pad Brake caliper piston...
Page 265: Front Brake
FRONT BRAKE d. Hold the dial gauge at a right angle against EAS30168 INTRODUCTION the brake disc surface. EWA14101 e. Measure the runout 1.5 mm (0.06 in) below WARNING the edge of the brake disc. Disc brake components rarely require disas- sembly.
Page 266 FRONT BRAKE d. Measure the brake disc runout. 3. Measure: • Brake pad wear limit “a” e. If out of specification, repeat the adjustment steps until the brake disc runout is within Out of specification Replace the brake specification. pads as a set. f.
Page 267 FRONT BRAKE c. Tighten the bleed screw. 8. Check: • Brake lever operation Brake caliper bleed screw Soft or spongy feeling Bleed the brake sys- 5 Nm (0.5 m·kgf, 3.6 ft·lbf) tem. d. Install the brake pads and brake pad spring. Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM (ABS)”...
Page 268 FRONT BRAKE EAS30172 DISASSEMBLING THE FRONT BRAKE Recommended brake component replacement schedule CALIPERS The following procedure applies to both of the Brake pads If necessary brake calipers. Piston seals Every two years 1. Remove: • Brake caliper pistons “1” Piston dust seals Every two years •...
Page 269 FRONT BRAKE replace the brake caliper piston dust seals 3. Install: and brake caliper piston seals. • Brake pads • Brake pad spring Specified brake fluid • Brake pad pin DOT 4 • Brake pad clips • Front brake caliper EAS30175 INSTALLING THE FRONT BRAKE CALIPERS Front brake caliper bolt...
Page 270 FRONT BRAKE (brake master cylinder body) Obstruction Blow out with compressed air. 2. Check: • Brake master cylinder kit Damage/scratches/wear Replace. 3. Check: • Brake fluid reservoir “1” • Brake fluid reservoir diaphragm holder “2” Cracks/damage Replace. • Brake fluid reservoir diaphragm “3” Damage/wear Replace.
Page 271 FRONT BRAKE with the punch mark “b” on the handlebar. EWA13540 WARNING • First, tighten the upper bolt, then the lower bolt. • Use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance.
Page 272 REAR BRAKE EAS20031 REAR BRAKE Removing the rear brake pads 5 Nm (0.5 m kgf, 3.6 ft Ibf) • • 27 Nm (2.7 m kgf, 20 ft lbf) • • 17 Nm (1.7 m kgf, 12 ft lbf) • • 2.5 Nm (0.25 m kgf, 1.8 ft lbf)
Page 273 REAR BRAKE Removing the rear brake master cylinder 32 Nm (3.2 m kgf, 23 ft lbf) • • 3.8 Nm (0.38 m kgf, 2.8 ft lbf) • • 1.5 Nm (0.15 m kgf, 1.1 ft lbf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) •...
Page 274: Rear Brake
REAR BRAKE Removing the rear brake caliper 32 Nm (3.2 m kgf, 23 ft lbf) • • 12 Nm (1.2 m kgf, 8.7 ft lbf) • • 27 Nm (2.7 m kgf, 20 ft lbf) • • Order Job/Parts to remove Q’ty Remarks Drain.
Page 275 REAR BRAKE Disassembling the rear brake caliper 5 Nm (0.5 m kgf, 3.6 ft Ibf) • • 17 Nm (1.7 m kgf, 12 ft lbf) • • 2.5 Nm (0.25 m kgf, 1.8 ft lbf) • • Order Job/Parts to remove Q’ty Remarks Screw plug...
Page 276 REAR BRAKE EAS30183 INTRODUCTION Brake disc thickness limit 4.5 mm (0.18 in) EWA14101 WARNING 5. Adjust: Disc brake components rarely require disas- • Brake disc runout sembly. Therefore, always follow these pre- Refer to “CHECKING THE FRONT BRAKE ventive measures: DISCS”...
Page 277 REAR BRAKE ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ Always install new brake pads, brake pad insu- 3. Lubricate: lators, brake pad shims, and brake pad spring as • Rear brake caliper bolts a set. Recommended lubricant Silicone grease ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect a clear plastic hose “1” tightly to the bleed screw “2”.
Page 278 REAR BRAKE the brake fluid from the entire brake system. 1. Remove: • Brake hose union bolt “1” • Brake hose gaskets “2” • Brake hose “3” Put the end of the brake hose into a container and pump out the brake fluid carefully. b.
Page 279 REAR BRAKE 2. Check: EWA13531 WARNING • Rear brake caliper bracket “1” Cracks/damage Replace. Proper brake hose routing is essential to in- Refer to “REAR WHEEL” on page 4-34. sure safe vehicle operation. ECA19080 NOTICE When installing the brake hose onto the brake caliper “1”, make sure the brake pipe “a”...
Page 280 REAR BRAKE 4. Fill: EAS30193 REMOVING THE REAR BRAKE MASTER • Brake fluid reservoir CYLINDER (with the specified amount of the specified 1. Remove: brake fluid) • Brake hose union bolt “1” Specified brake fluid • Brake hose gaskets “2” DOT 4 •...
Page 281 REAR BRAKE is already in the system. Mixing brake fluids EAS31743 THE REAR BRAKE MASTER CYLINDER may result in a harmful chemical reaction, ECA23000 leading to poor brake performance. NOTICE • When refilling, be careful that water does Do not disassemble the rear brake master not enter the brake fluid reservoir.
Page 282 ABS (Anti-lock Brake System) EAS20032 ABS (Anti-lock Brake System) Removing the hydraulic unit assembly 16 Nm (1.6 m kgf, 12 ft lbf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 16 Nm (1.6 m kgf, 12 ft lbf) •...
Page 283 ABS (Anti-lock Brake System) Removing the hydraulic unit assembly 16 Nm (1.6 m kgf, 12 ft lbf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 16 Nm (1.6 m kgf, 12 ft lbf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) •...
Page 284 7. Front brake caliper 8. Rear wheel sensor 9. Rear wheel sensor rotor 10.Rear brake caliper 11.Yamaha diagnostic tool coupler 12.ABS motor fuse 13.Hydraulic unit brake pipe (hydraulic unit to front brake calipers) 14.Hydraulic unit brake pipe (front brake master cylinder to hydraulic unit) 15.Hydraulic unit brake pipe (rear brake master...
Page 285 ABS (Anti-lock Brake System) EAS30197 REMOVING THE HYDRAULIC UNIT ASSEMBLY ECA18230 NOTICE Unless necessary, avoid removing and in- stalling the brake pipes of the hydraulic unit assembly. EWA13930 WARNING Refill with the same type of brake fluid that is 2. Remove: already in the system.
Page 286 ABS (Anti-lock Brake System) Hydraulic unit assembly nut 8 Nm (0.8 m·kgf, 5.8 ft·lbf) 2. Remove: • Rubber plugs or bolts (M10 1.0) 3. Install: • Hydraulic unit brake pipe 4. Tighten: • Hydraulic unit brake pipe flare nuts Hydraulic unit brake pipe flare nut EAS30198 16 Nm (1.6 m·kgf, 12 ft·lbf) CHECKING THE HYDRAULIC UNIT...
Page 287 Mixing brake fluids • For the brake line routing confirmation, use the may result in a harmful chemical reaction, diagnosis mode of the Yamaha diagnostic tool. leading to poor brake performance. • Before performing the brake line routing confir- •...
Page 288 “1”, brake pedal “2”, and again in the brake lever “1”, in this order. 6. Start the Yamaha diagnostic tool and display the diagnosis mode screen. 7. Select code No. 2, “Brake line routing confir- mation”.
Page 289 • For the ABS reaction-force confirmation, use the diagnosis mode of the Yamaha diagnostic 6. Start the Yamaha diagnostic tool and display tool. For more information, refer to the opera- the diagnosis mode screen.
Page 290 12.Turn the main switch to “OFF”. 13.Remove the Yamaha diagnostic tool coupler from the Yamaha diagnostic tool coupler, and then install the protective cap. 14.Turn the main switch to “ON”. 15.Set the start/engine stop switch to “ ”.
Page 291 HANDLEBARS EAS20033 HANDLEBARS Removing the handlebars 26 Nm (2.6 m kgf, 19 ft lbf) 7 Nm (0.7 m kgf, 5.1 ft Ibf) 115 Nm (11.5 m kgf, 83 ft lbf) • • • • • • 2.5 Nm (0.25 m kgf, 1.8 ft lbf) •...
Page 292 HANDLEBARS Removing the handlebars 26 Nm (2.6 m kgf, 19 ft lbf) 7 Nm (0.7 m kgf, 5.1 ft Ibf) 115 Nm (11.5 m kgf, 83 ft lbf) • • • • • • 2.5 Nm (0.25 m kgf, 1.8 ft lbf) •...
Page 293 HANDLEBARS EAS30203 REMOVING THE HANDLEBARS 1. Stand the vehicle on a level surface. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. 2. Remove: • Handlebar grip “1” Blow compressed air between the left handlebar and the handlebar grip, and gradually push the EAS30205 INSTALLING THE HANDLEBARS...
Page 294 HANDLEBARS 4. Install: 7. Install: • Handlebar switch screw (right) • Handlebar switch screw (left) Handlebar switch screw Handlebar switch screw 3.5 Nm (0.35 m·kgf, 2.5 ft·lbf) 3.5 Nm (0.35 m·kgf, 2.5 ft·lbf) Align the projection “a” on the right handlebar Align the projection “a”...
Page 295 HANDLEBARS ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 9. Adjust: • Throttle grip free play Refer to “ADJUSTING THE CLUTCH LEVER FREE PLAY” on page 3-13. Throttle grip free play 3.0–5.0 mm (0.12–0.20 in) 10.Adjust: • Clutch lever free play Refer to “CHECKING THE THROTTLE GRIP” on page 3-36. Clutch lever free play 10.0–15.0 mm (0.39–0.59 in) 4-78...
Page 296 FRONT FORK (for YZF-R1) EAS20034 FRONT FORK (for YZF-R1) Removing the front fork legs (for YZF-R1) 32 Nm (3.2 m kgf, 23 ft lbf) 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • • • 26 Nm (2.6 m kgf, 19 ft lbf) •...
Page 297 FRONT FORK (for YZF-R1) Disassembling the front fork legs (for YZF-R1) Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of the front fork legs. Cap bolt O-ring Guide Spacer Fork spring Locknut Damper adjusting rod 1 Damper adjusting rod 2 Dust seal Oil seal clip...
Page 298 FRONT FORK (for YZF-R1) EAS30206 EAS30207 REMOVING THE FRONT FORK LEGS (for DISASSEMBLING THE FRONT FORK LEGS YZF-R1) (for YZF-R1) The following procedure applies to both of the The following procedure applies to both of the front fork legs. front fork legs. 1.
Page 299 FRONT FORK (for YZF-R1) ECA17390 NOTICE When loosening the nut, be sure not to break the projections on the cap bolt collar of the cap bolt. 5. Remove: • Outer tube ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Hold the front fork leg horizontally. b. Securely clamp the brake caliper bracket in a vise with soft jaws.
Page 300 FRONT FORK (for YZF-R1) Damage/wear Replace. Obstruction Blow out all of the oil passag- es with compressed air. ECA19110 NOTICE • The front fork leg has a very sophisticated internal construction, which are particular- ly sensitive to foreign material. • When disassembling and assembling the front fork leg, do not allow any foreign ma- terial to enter the front fork.
Page 301 FRONT FORK (for YZF-R1) replace the following parts: 3. Lubricate: –Inner tube bushing • Inner tube’s outer surface –Outer tube bushing Recommended oil –Oil seal YZF-R1 Suspension oil M1 or –Oil seal clip equivalent –Dust seal –O-ring 4. Install: • Before assembling the front fork leg, make •...
Page 302 FRONT FORK (for YZF-R1) (with the fork seal driver “3”) 9. Install: • Dust seal “1” Fork seal driver (with the fork seal driver “2”) 90890-01442 Adjustable fork seal driver (36–46 Fork seal driver 90890-01442 YM-01442 Adjustable fork seal driver (36–46 YM-01442 7.
Page 303 FRONT FORK (for YZF-R1) Recommended oil YZF-R1 Suspension oil M1 or equivalent Quantity YZF-R1 368.0 cm³ (12.44 US oz, 12.98 Imp.oz) ECA14230 NOTICE • Be sure to use the recommended fork oil. Other oils may have an adverse effect on 15.Install: front fork performance.
Page 304 FRONT FORK (for YZF-R1) f. Install the fork spring compressor. Front fork cap bolt locknut (for g. Press down on the spacer with the fork spring YZF-R1) compressor “1”. 15 Nm (1.5 m·kgf, 11 ft·lbf) h. Pull up the rod puller and install the rod holder “2”...
Page 305 FRONT FORK (for YZF-R1) 2. Tighten: • Lower bracket pinch bolts “1” and “2” When installing the front fork legs, make sure that the spring preload adjusting nuts are posi- Lower bracket pinch bolt tioned at the angles shown in the illustration. 23 Nm (2.3 m·kgf, 17 ft·lbf) 55-65°...
Page 306 FRONT FORK (for YZF-R1) Refer to “ADJUSTING THE FRONT FORK LEGS (for YZF-R1)” on page 3-23. 4-89...
Page 307 FRONT FORK (for YZF-R1M) EAS20169 FRONT FORK (for YZF-R1M) Removing the front fork legs (for YZF-R1M) 32 Nm (3.2 m kgf, 23 ft lbf) 7 Nm (0.7 m kgf, 5.1 ft Ibf) 26 Nm (2.6 m kgf, 19 ft lbf) •...
Page 308 FRONT FORK (for YZF-R1M) Disassembling the front fork legs (for YZF-R1M) 20 Nm (2.0 m kgf, 14 ft lbf) 19 Nm (1.9 m kgf, 14 ft lbf) • • • • 68 Nm (6.8 m kgf, 49 ft lbf) • •...
Page 309 FRONT FORK (for YZF-R1M) EAS31648 REMOVING THE FRONT FORK LEGS (for YZF-R1M) The following procedure applies to both of the front fork legs. 1. Stand the vehicle on a level surface. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over.
Page 310 FRONT FORK (for YZF-R1M) • Oil seal Front fork cap bolt wrench 42mm • Washer 90890-01575 YM-01575 6. Remove: • Damper rod assembly b. Hold the spring preload adjusting bolt “5” and Remove the damper rod assembly with the loosen the locknut. damper rod holder “1”.
Page 311 FRONT FORK (for YZF-R1M) Cracks/damage Replace. 2. Measure: • Spring free length “a” EAS31651 ASSEMBLING THE FRONT FORK LEGS (for Out of specification Replace. YZF-R1M) Fork spring free length The following procedure applies to both of the YZF-R1M 260.0 mm (10.24 in) front fork legs.
Page 312 FRONT FORK (for YZF-R1M) 2. Tighten: • Damper rod assembly Front fork damper rod assembly (for YZF-R1M) 68 Nm (6.8 m·kgf, 49 ft·lbf) Tighten the damper rod assembly with the damper rod holder “1”. Damper rod holder 90890-01504 Damper rod holder YM-01504 5.
Page 313 FRONT FORK (for YZF-R1M) Recommended oil YZF-R1M Suspension oil M1 or Ohlins R&T 43 Quantity YZF-R1M 405.0 cm³ (13.69 US oz, 14.28 Imp.oz) ECA14230 NOTICE • Be sure to use the recommended fork oil. Other oils may have an adverse effect on 8.
Page 314 FRONT FORK (for YZF-R1M) 14.Install: e. Remove the rod puller. • Spacer “1” f. Install the cap bolt completely, and then fin- • Fork spring “2” ger tighten the cap bolt. • Upper spring seat “3” EWA13670 WARNING • Locknut “4” Always use a new cap bolt O-ring.
Page 315 FRONT FORK (for YZF-R1M) bracket pinch bolts. EWA13680 WARNING Make sure the brake hoses are routed prop- erly. Align the outer tube with the position “a” as shown in the illustration. • Handlebar bolt “3” Handlebar bolt 7 Nm (0.7 m·kgf, 5.1 ft·lbf) •...
Page 316 FRONT FORK (for YZF-R1M) cable, and handlebar switch leads are routed properly. Refer to “CABLE ROUTING” on page 2-51. 5. Install: • Plastic locking tie “1” Fasten the front brake hose to the right front fork leg with the plastic locking tie. 6.
Page 317 STEERING HEAD EAS20035 STEERING HEAD Removing the lower bracket 23 Nm (2.3 m kgf, 17 ft lbf) • • 11 Nm (1.1 m kgf, 8.0 ft lbf) • • 52 Nm (5.2 m kgf, 38 ft lbf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) 14 Nm (1.4 m...
Page 318 STEERING HEAD Removing the lower bracket 23 Nm (2.3 m kgf, 17 ft lbf) • • 11 Nm (1.1 m kgf, 8.0 ft lbf) • • 52 Nm (5.2 m kgf, 38 ft lbf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) 14 Nm (1.4 m...
Page 319 STEERING HEAD Damage/pitting Replace the bearings and EAS30213 REMOVING THE LOWER BRACKET bearing races as a set. 1. Stand the vehicle on a level surface. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. 2.
Page 320 STEERING HEAD damper assembly. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ • Steering damper rod 4. Check: Bends/scratch Replace the steering • Upper bracket damper assembly. • Lower bracket • Bearing (along with the steering stem) Damage/pitting Replace the steering Bends/cracks/damage Replace. damper assembly. EAS30216 INSTALLING THE STEERING HEAD 1.
Page 321 REAR SHOCK ABSORBER ASSEMBLY EAS20036 REAR SHOCK ABSORBER ASSEMBLY Removing the rear shock absorber assembly (for YZF-R1) 40 Nm (4.0 m kgf, 29 ft lbf) • • 40 Nm (4.0 m kgf, 29 ft lbf) • • 40 Nm (4.0 m kgf, 29 ft lbf) •...
Page 322 REAR SHOCK ABSORBER ASSEMBLY Removing the rear shock absorber assembly (for YZF-R1) 40 Nm (4.0 m kgf, 29 ft lbf) • • 40 Nm (4.0 m kgf, 29 ft lbf) • • 40 Nm (4.0 m kgf, 29 ft lbf) •...
Page 323 REAR SHOCK ABSORBER ASSEMBLY Removing the rear shock absorber assembly (for YZF-R1M) 40 Nm (4.0 m kgf, 29 ft lbf) • • 40 Nm (4.0 m kgf, 29 ft lbf) • • 40 Nm (4.0 m kgf, 29 ft lbf) •...
Page 324 REAR SHOCK ABSORBER ASSEMBLY Removing the rear shock absorber assembly (for YZF-R1M) 40 Nm (4.0 m kgf, 29 ft lbf) • • 40 Nm (4.0 m kgf, 29 ft lbf) • • 40 Nm (4.0 m kgf, 29 ft lbf) •...
Page 325 REAR SHOCK ABSORBER ASSEMBLY EAS30826 HANDLING THE REAR SHOCK ABSORBER EWA13740 WARNING This rear shock absorber contains highly compressed nitrogen gas. Before handling the rear shock absorber, read and make sure you understand the following information. The manufacturer cannot be held responsi- ble for property damage or personal injury that may result from improper handling of the rear shock absorber.
Page 326 REAR SHOCK ABSORBER ASSEMBLY • Collar “3” 4. Remove: • Relay arm “4” • Oil seal • Bearing “1” Pull out the collar “3” from the left side of the ve- hicle. Remove the bearing with a socket “2” that matches its outside diameter.
Page 327 REAR SHOCK ABSORBER ASSEMBLY Damage/pitting Replace. EAS30222 INSTALLING THE RELAY ARM 3. Check: 1. Lubricate: • Collars • Collars Damage/scratches Replace. • Oil seals EAS31654 Recommended lubricant ASSEMBLING THE REAR SHOCK Lithium-soap-based grease ABSORBER ASSEMBLY 1. Install: 2. Install: • Bearing “1” •...
Page 328 REAR SHOCK ABSORBER ASSEMBLY EAS30225 INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY 1. Install: • Rear shock absorber assembly • Relay arm • Connecting arm • Install the rear shock absorber assembly upper bolt, relay arm bolt, connecting arm lower bolt and connecting arm upper bolt from the left.
Page 329: Removing The Swingarm
SWINGARM EAS20037 SWINGARM Removing the swingarm 65 Nm (6.5 m kgf, 47 ft lbf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) 16 Nm (1.6 m kgf, 12 ft lbf) •...
Page 330 SWINGARM 5. Remove: EAS30226 REMOVING THE SWINGARM • Pivot shaft nut 1. Stand the vehicle on a level surface. • Pivot shaft ring nut “1” EWA13120 WARNING Loosen the pivot shaft ring nut with the ring nut Securely support the vehicle so that there is wrench “2”.
Page 331 SWINGARM EWA13770 WARNING Do not attempt to straighten a bent pivot shaft. 3. Wash: • Pivot shaft • Dust covers • Collar • Bushing • Washer EAS30228 INSTALLING THE SWINGARM Recommended cleaning solvent 1. Lubricate: Kerosene • Dust covers 4. Check: •...
Page 332 SWINGARM Tighten the pivot shaft ring nut with the ring nut wrench “2”. Ring nut wrench 90890-01507 Ring nut wrench YM-01507 5. Install: • Pivot shaft nut “1” A. Left side B. Right side Pivot shaft nut 105 Nm (10.5 m·kgf, 76 ft·lbf) 3.
Page 333 CHAIN DRIVE EAS20038 CHAIN DRIVE Removing the drive chain 10 Nm (1.0 m kgf, 7.2 ft lbf) • • 125 Nm (12.5 m kgf, 90 ft lbf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 28 Nm (2.8 m kgf, 20 ft lbf) 10 Nm (1.0 m...
Page 334 CHAIN DRIVE Drive chain 15-link section length “a” = EAS30229 REMOVING THE DRIVE CHAIN (length “b” between pin inner sides + length 1. Stand the vehicle on a level surface. “c” between pin outer sides)/2 EWA13120 WARNING • When measuring a 15-link section of the drive Securely support the vehicle so that there is chain, make sure that the drive chain is taut.
Page 335 CHAIN DRIVE ECA19090 NOTICE • This vehicle has a drive chain with small rubber O-rings “1” between the drive chain side plates. Never use high-pressure water or air, steam, gasoline, certain solvents (e.g., benzine), or a coarse brush to clean the drive chain.
Page 336 CHAIN DRIVE EAS30234 INSTALLING THE DRIVE CHAIN 1. Install: • Drive chain ECA17410 NOTICE Be sure to put on safety goggles when work- ing. Install the drive chain joint with the drive chain cut & rivet tool. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 2. Lubricate: Drive chain cut &...
Page 337 CHAIN DRIVE on page 4-120. 7. Adjust: • Drive chain slack Refer to “ADJUSTING THE DRIVE CHAIN SLACK” on page 3-19. Drive chain slack 25.0–35.0 mm (0.98–1.38 in) ECA13550 NOTICE A drive chain that is too tight will overload 5. Install: the engine and other vital parts, and one that •...
Page 338 CHAIN DRIVE c. Tighten both locknuts. Be sure to place the shift rod joints in parallel. The allowable twist of the shift rod joints is ±5 . Shift rod locknut 7 Nm (0.7 m·kgf, 5.1 ft·lbf) d. Make sure the installed shift rod length is within specification.
Page 339 ENGINE ENGINE INSPECTION ..................5-1 MEASURE THE COMPRESSION PRESSURE.........5-1 ENGINE REMOVAL..................5-3 REMOVING THE ENGINE .................5-7 INSTALLING THE ENGINE................5-7 INSTALLING THE EXHAUST PIPE AND MUFFLER.........5-8 CAMSHAFTS....................5-9 REMOVING THE CAMSHAFTS...............5-13 REMOVING THE ROCKER ARMS AND ROCKER ARM SHAFTS..5-14 CHECKING THE CAMSHAFTS ...............5-14 CHECKING THE ROCKER ARMS AND ROCKER ARM SHAFTS ..5-16 CHECKING THE TIMING CHAIN AND CAMSHAFT SPROCKET ..5-16 CHECKING THE TIMING CHAIN GUIDES..........5-17 CHECKING THE TIMING CHAIN TENSIONER........5-17...
Page 340 OIL PUMP.......................5-45 REMOVING THE OIL PAN...............5-48 CHECKING THE SPROCKET AND CHAIN..........5-48 CHECKING THE OIL PUMP ..............5-49 CHECKING THE RELIEF VALVE ............5-49 CHECKING THE OIL DELIVERY PIPES ..........5-50 CHECKING THE OIL STRAINER ............5-50 ASSEMBLING THE OIL PUMP..............5-50 INSTALLING THE OIL PUMP ..............5-50 INSTALLING THE OIL PAN ..............5-52 CLUTCH ......................5-53 REMOVING THE CLUTCH ..............5-56...
Page 341 INSTALLING THE CRANKSHAFT ............5-88 INSTALLING THE BALANCER ASSEMBLY..........5-89 TRANSMISSION.....................5-90 REMOVING THE TRANSMISSION ............5-94 CHECKING THE SHIFT FORKS..............5-94 CHECKING THE SHIFT DRUM ASSEMBLY...........5-95 CHECKING THE TRANSMISSION ............5-95 ASSEMBLING THE MAIN AXLE AND DRIVE AXLE .......5-95 INSTALLING THE TRANSMISSION ............5-96...
Page 342 ENGINE INSPECTION EAS20041 ENGINE INSPECTION EAS30249 MEASURE THE COMPRESSION PRESSURE The following procedure applies to all of the cyl- inders. Insufficient compression pressure will result in a loss of performance. 1. Measure: 5. Measure: • Valve clearance • Compression pressure Out of specification Adjust.
Page 343 ENGINE INSPECTION Compression pressure (with oil applied into the cylinder) Reading Diagnosis Piston ring(s) wear or Higher than without oil damage Repair. Piston, valves, cylinder Same as without oil head gasket possibly defective Repair. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 6. Install: • Spark plugs Spark plug 13 Nm (1.3 m·kgf, 9.4 ft·lbf) Spark plug (new)
Page 344 ENGINE REMOVAL EAS20042 ENGINE REMOVAL Removing the muffler and exhaust pipe 10 Nm (1.0 m kgf, 7.2 ft lbf) 10 Nm (1.0 m kgf, 7.2 ft lbf) 6 Nm (0.6 m kgf, 4.3 ft Ibf) • • • • • •...
Page 345 ENGINE REMOVAL Removing the muffler and exhaust pipe 10 Nm (1.0 m kgf, 7.2 ft lbf) 10 Nm (1.0 m kgf, 7.2 ft lbf) 6 Nm (0.6 m kgf, 4.3 ft Ibf) • • • • • • 2.0 Nm (0.20 m kgf, 1.4 ft lbf) •...
Page 346 ENGINE REMOVAL Disconnecting the leads and hoses 3.5 Nm (0.35 m kgf, 2.5 ft lbf) • • 7 Nm (0.7 m kgf, 5.1 ft lbf) • • Order Job/Parts to remove Q’ty Remarks Air filter case Refer to “AIR FILTER CASE” on page 7-4. Refer to “AIR INDUCTION SYSTEM”...
Page 347 ENGINE REMOVAL Removing the engine 56 Nm (5.6 m kgf, 41 ft lbf) • • 70 Nm (7.0 m kgf, 51 ft lbf) • • 56 Nm (5.6 m kgf, 41 ft lbf) • • 70 Nm (7.0 m kgf, 51 ft lbf) •...
Page 348 ENGINE REMOVAL EAS30250 REMOVING THE ENGINE • Tighten the engine mounting adjust bolt to 1. Loosen: specification with the pivot shaft wrench. • Engine mounting adjust bolt • Make sure that the flange on the engine mounting adjust bolt contacts the engine. Loosen the engine mounting adjust bolt with the pivot shaft wrench “1”.
Page 349 ENGINE REMOVAL EAS30252 INSTALLING THE EXHAUST PIPE AND MUFFLER 1. Install: • Exhaust pipe • Gasket “1” (to exhaust chamber) • Muffler When installing the gasket, install it so that the chamfered side “a” of the gasket faces the ex- haust pipe side as shown in the illustration.
Page 350 CAMSHAFTS EAS20043 CAMSHAFTS Removing the cylinder head cover 13 Nm (1.3 m kgf, 9.4 ft lbf) • • 8 Nm (0.8 m kgf, 5.8 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft lbf) • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS (1)”...
Page 351 CAMSHAFTS Removing the camshafts 8 Nm (0.8 m kgf, 5.8 ft Ibf) 10 Nm (1.0 m kgf, 7.2 ft lbf) • • • • 8 Nm (0.8 m kgf, 5.8 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Crankshaft end cover/Timing mark accessing Refer to “GENERATOR”...
Page 352 CAMSHAFTS Removing the timing chain and timing chain guide 72 Nm (7.2 m kgf, 52 ft lbf) • • 9 10 10 Nm (1.0 m kgf, 7.2 ft lbf) • • 6 Nm (0.6 m kgf, 4.3 ft Ibf) • •...
Page 353 CAMSHAFTS Removing the rocker arms 10 Nm (1.0 m kgf, 7.2 ft lbf) • • 6 Nm (0.6 m kgf, 4.3 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft lbf) • • Order Job/Parts to remove Q’ty Remarks Engine Refer to “ENGINE REMOVAL”...
Page 354 CAMSHAFTS EAS30256 REMOVING THE CAMSHAFTS 1. Remove: • Timing mark accessing bolt “1” • Crankshaft end cover “2” 4. Remove: • Camshaft cap “1” ECA13720 NOTICE To prevent damage to the cylinder head, 2. Align: camshafts or camshaft caps, loosen the •...
Page 355 CAMSHAFTS Camshaft lobe dimensions Lobe height (Intake) 35.210–35.310 mm (1.3862– 1.3902 in) Limit 35.160 mm (1.3842 in) Base circle diameter (Intake) 28.150–28.250 mm (1.1083– 1.1122 in) Limit 28.100 mm (1.1063 in) Lobe height (Exhaust) EAS31655 REMOVING THE ROCKER ARMS AND 34.220–35.220 mm (1.3472–...
Page 356 CAMSHAFTS 4. Measure: a. Camshaft cap bolt (black): 40 mm (1.57 in) • Camshaft-journal-to-camshaft-cap clearance b. Camshaft cap bolt (silver): 35 mm (1.38 in) Out of specification Measure the camshaft A. Intake side journal diameter. B. Exhaust side Camshaft-journal-to-camshaft- cap clearance •...
Page 357 CAMSHAFTS Camshaft journal diameter 25.459–25.472 mm (1.0023– 1.0028 in) 4. Measure: • Rocker arm shaft outside diameter “a” Out of specification Replace. Rocker arm shaft outside diame- EAS30259 CHECKING THE ROCKER ARMS AND 7.967–7.979 mm (0.3137–0.3141 ROCKER ARM SHAFTS The following procedure applies to all of the Limit 7.936 mm (0.3124 in) rocker arms and rocker arm shafts.
Page 358 CAMSHAFTS 2. Check: “a”, and turn the timing chain tensioner body “3” • Camshaft sprocket in direction “b” until it stops. More than 1/4 tooth wear “a” Replace the camshaft sprockets and the timing chain as a Valve spring compressor set.
Page 359 CAMSHAFTS EAS31744 ASSEMBLING THE TIMING CHAIN COVER 1. Install: • Oil seal “1” Install the oil seal with a socket “2” that matches its outside diameter. Installed depth “a” 4.0–4.5 mm (0.16–0.18 in) EAS31715 2. Install: INSTALLING THE TIMING CHAIN COVER •...
Page 360 CAMSHAFTS EAS30269 INSTALLING THE CAMSHAFTS 1. Remove: • Timing mark accessing bolt “1” • Crankshaft end cover “2” 4. Install: • Camshaft cap Make sure each camshaft cap is installed in its original place. Refer to the identification marks 2. Align: as follows: •...
Page 361 CAMSHAFTS evenly or damage to the cylinder head, camshaft caps, and camshafts will result. • Do not turn the crankshaft when installing the camshaft to avoid damage or improper valve timing. ECA23010 NOTICE There are two kinds of camshaft cap bolts with different lengths.
Page 362 CAMSHAFTS is aligned with the generator rotor cover slot “b”. • Camshaft sprocket timing mark “c” Make sure the punch mark “c” on the cam- shaft sprocket is aligned with the cylinder head mating surface “d”. Out of alignment Adjust. Refer to the installation steps above.
Page 363 CAMSHAFTS Spark plug 13 Nm (1.3 m·kgf, 9.4 ft·lbf) Spark plug (new) 18 Nm (1.8 m·kgf, 13 ft·lbf) • Before installing the spark plug, clean the spark plug and gasket surface. • If the spark plug is a new one, tighten it to 18 Nm (1.8 m·kgf, 13 ft·lbf).
Page 364 CYLINDER HEAD EAS20044 CYLINDER HEAD Removing the cylinder head 12 Nm (1.2 m kgf, 8.7 ft lbf) • • 16 Nm (1.6 m kgf, 12 ft lbf) • • 10 Nm (1.0 m kgf, 7.2 ft lbf) • • 25 Nm (2.5 m kgf, 18 ft lbf) •...
Page 365 CYLINDER HEAD EAS30276 REMOVING THE CYLINDER HEAD 1. Remove: • Intake camshaft • Exhaust camshaft Refer to “REMOVING THE CAMSHAFTS” on page 5-13. 2. Remove: • Cylinder head bolt (M6) ( 2) • Cylinder head bolt (M9) ( 10) • Loosen the bolts in the proper sequence as ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼...
Page 366 CYLINDER HEAD Refer to “INSTALLING THE CAMSHAFTS” on page 5-19. 2. Install: • Cylinder head • Cylinder head bolt (M6) ( 2) • Cylinder head bolt (M9) ( 10) • Pass the timing chain through the timing chain cavity. • Lubricate the cylinder head bolt (M9) thread and mating surface with engine oil.
Page 367 VALVES AND VALVE SPRINGS EAS20045 VALVES AND VALVE SPRINGS Removing the valves and valve springs Order Job/Parts to remove Q’ty Remarks Cylinder head Refer to “CYLINDER HEAD” on page 5-23. Exhaust valve pad Exhaust valve cotter Exhaust valve spring retainer The valve spring is part of a set together with the valve spring seat.
Page 368 VALVES AND VALVE SPRINGS Removing the valves and valve springs Order Job/Parts to remove Q’ty Remarks Intake valve spring retainer The valve spring is part of a set together with the valve spring seat. Intake valve spring Refer to “CHECKING THE VALVE SPRINGS”...
Page 369 VALVES AND VALVE SPRINGS “1” and the valve spring compressor attachment EAS30283 REMOVING THE VALVES “2”. The following procedure applies to all of the valves and related components. Valve spring compressor 90890-04019 Before removing the internal parts of the cylinder Valve spring compressor head (e.g., valves, valve springs, valve seats), YM-04019...
Page 370 VALVES AND VALVE SPRINGS • Valve-stem-to-valve-guide clearance = Valve guide inside diameter “a” - Valve stem diameter “b” Valve-stem-to-valve-guide clear- ance (intake) 0.010–0.037 mm (0.0004–0.0015 Limit 0.080 mm (0.0032 in) Valve-stem-to-valve-guide clear- b. Install the new valve guide with the valve ance (exhaust) guide installer “2”...
Page 371 VALVES AND VALVE SPRINGS Valve guide remover (ø4.5) 90890-04116 Valve guide remover (4.5 mm) YM-04116 Valve guide remover (ø5) 90890-04097 Valve guide remover (5.0 mm) YM-04097 Valve guide installer (ø4.5) 90890-04117 Valve guide installer (4.5 mm) EAS30285 YM-04117 CHECKING THE VALVE SEATS Valve guide installer (ø5) The following procedure applies to all of the 90890-04098...
Page 372 VALVES AND VALVE SPRINGS b. Install the valve into the cylinder head. b. Apply molybdenum disulfide oil onto the c. Press the valve through the valve guide and valve stem. onto the valve seat to make a clear impres- c. Install the valve into the cylinder head. sion.
Page 373 VALVES AND VALVE SPRINGS cation, reface and lap the valve seat. spring and valve spring seat as a set. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ b. Installed length EAS30286 CHECKING THE VALVE SPRINGS Installed compression spring force (intake) ECA23020 NOTICE 171.40–197.20 N (17.48–20.11 kgf, 38.53–44.33 lbf) The valve spring and valve spring seat con- Installed compression spring stitute a set to maintain high precision.
Page 374 VALVES AND VALVE SPRINGS valve spring and valve spring seat as a set. • When installing the valve spring and valve spring seat, be sure to install them onto their original positions. The following procedure applies to all of the valve lifters.
Page 375 VALVES AND VALVE SPRINGS Valve spring compressor 90890-04019 Valve spring compressor YM-04019 Valve spring compressor attach- ment 90890-01243 Valve spring compressor adapter (26 mm) YM-01253-1 5. To secure the valve cotters onto the valve stem, lightly tap the valve tip with a soft-face hammer.
Page 376 GENERATOR EAS20134 GENERATOR Removing the stator coil and generator rotor 10 Nm (1.0 m kgf, 7.2 ft lbf) • • 6 Nm (0.6 m kgf, 4.3 ft Ibf) • • 15 Nm (1.5 m kgf, 11 ft lbf) • • 85 Nm (8.5 m kgf, 61 ft lbf)
Page 377 GENERATOR EAS30829 REMOVING THE GENERATOR Flywheel puller 90890-01404 1. Remove: Flywheel puller • Generator rotor bolt “1” YM-01404 • Washer While holding the generator rotor “2” with the ro- tor holding tool “3”, loosen the generator rotor bolt. 15mm pin type rotor holding tool 90890-04171 YM-04171 EAS30830...
Page 378 To route the stator coil lead, refer to “CABLE ROUTING” on page 2-51. 3. Apply: • Sealant (onto the stator coil assembly lead grommet) Yamaha bond No. 1215 90890-85505 (Three bond No.1215®) 4. Install: • Generator cover gasket • Generator cover •...
Page 379 STARTER CLUTCH EAS20049 STARTER CLUTCH Removing the starter clutch 14 Nm (1.4 m kgf, 10 ft lbf) • • Order Job/Parts to remove Q’ty Remarks Clutch housing assembly Refer to “CLUTCH” on page 5-53. Starter clutch gear Bearing Starter clutch assembly Circlip Starter clutch idle gear 5-38...
Page 380: Starter Clutch
STARTER CLUTCH EAS30305 REMOVING THE STARTER CLUTCH 1. Remove: • Starter clutch bolt “1” • While holding the clutch housing assembly “2” with the sheave holder “3”, remove the starter clutch bolt. • Fix the flat surface of the clutch housing as- sembly with the sheave holder.
Page 381 STARTER CLUTCH • While holding the clutch housing assembly “1” with the sheave holder “2”, tighten the starter clutch holder bolt “3”. • Fix the flat surface of the clutch housing as- sembly with the sheave holder. Sheave holder 90890-01701 Primary clutch holder YS-01880-A 5-40...
Page 382 ELECTRIC STARTER EAS20052 ELECTRIC STARTER Removing the starter motor 3.5 Nm ( 0.35 m kgf, 2.5 ft lbf) • • 10 Nm (1.0 m kgf, 7.2 ft lbf) • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS (1)” on page Rider seat 4-1.
Page 383 ELECTRIC STARTER Disassembling the starter motor 4.5 Nm (0.45 m kgf, 3.3 ft lbf) • • Order Job/Parts to remove Q’ty Remarks O-ring Starter motor front cover Starter motor yoke Armature assembly Gasket Brush holder set Starter motor rear cover 5-42...
Page 384 ELECTRIC STARTER EAS30325 CHECKING THE STARTER MOTOR 1. Check: • Commutator Dirt Clean with 600 grit sandpaper. 2. Measure: • Mica undercut “a” Out of specification Scrape the mica to the proper measurement with a hacksaw blade that has been grounded to fit the commutator. Mica undercut (depth) 1.
Page 385 ELECTRIC STARTER 6. Check: • Gear teeth Damage/wear Replace the starter motor. 7. Check: • Bearing • Oil seal Damage/wear Replace the starter motor front cover. EAS30326 ASSEMBLING THE STARTER MOTOR 1. Install: • Starter motor rear cover “1” • Starter motor yoke “2” •...
Page 386 OIL PUMP EAS20054 OIL PUMP Removing the oil pan and oil pump 10 Nm (1.0 m kgf, 7.2 ft lbf) • • 6 Nm (0.6 m kgf, 4.3 ft Ibf) • • 3.0 Nm (0.30 m kgf, 2.2 ft Ibf) •...
Page 387 OIL PUMP Removing the oil pan and oil pump 10 Nm (1.0 m kgf, 7.2 ft lbf) • • 6 Nm (0.6 m kgf, 4.3 ft Ibf) • • 3.0 Nm (0.30 m kgf, 2.2 ft Ibf) • • Specified angle 90° 10 Nm (1.0 m kgf, 7.2 ft lbf)
Page 388 OIL PUMP Disassembling the oil pump 10 Nm (1.0 m kgf, 7.2 ft lbf) • • Order Job/Parts to remove Q’ty Remarks Oil pump cover Dowel pin Oil pump outer rotor Oil pump inner rotor Oil pump driven sprocket 5-47...
Page 389 OIL PUMP EAS30333 REMOVING THE OIL PAN 1. Remove: • Oil pan “1” • Gasket • Dowel pins Loosen each bolt 1/4 of a turn at a time, in stag- es and in a crisscross pattern. After all of the bolts are fully loosened, remove them.
Page 390 OIL PUMP EAS30337 CHECKING THE OIL PUMP 1. Check: • Oil pump driven sprocket “1” Cracks/damage/wear Replace. • Oil pump housing “2” Cracks/damage/wear Replace. 2. Measure: • Outer-rotor-to-oil-pump-housing clearance “a” • Oil-pump-housing-to-inner-rotor-and-outer- 1. Inner rotor rotor clearance “b” 2. Outer rotor Out of specification Replace the defective 3.
Page 391 OIL PUMP • Oil pump shaft (with the recommended lubricant) Recommended lubricant Engine oil 2. Install: • Oil pump driven sprocket “1” • Pin “2” • Inner rotor “3” • Outer rotor “4” • Oil pump cover “5” EAS30339 CHECKING THE OIL DELIVERY PIPES •...
Page 392 OIL PUMP 4. Install: • O-ring • Oil pipe 1 “1” Oil pipe 1 bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) LOCTITE® • O-ring • Oil delivery pipe 1 “2” • Oil strainer “3” 2. Install: Oil strainer bolt • Washer 10 Nm (1.0 m·kgf, 7.2 ft·lbf) •...
Page 393 OIL PUMP EAS30345 INSTALLING THE OIL PAN 1. Install: • Oil pan gasket • Oil pan • Oil pan bolt 2. Tighten: • Oil pan bolt Oil pan bolt 1st: 6 Nm (0.6 m·kgf, 4.3 ft·lbf) 2nd: 3.0 Nm (0.30 m·kgf, 2.2 ft·lbf) Specified angle 90 Following the tightening order, loosen the bolt...
Page 394 CLUTCH EAS20055 CLUTCH Removing the clutch cover 7 Nm (0.7 m kgf, 5.1 ft lbf) • • (10) 6 Nm (0.6 m kgf, 4.3 ft Ibf) • • 3.0 Nm (0.30 m kgf, 2.2 ft Ibf) • • Specified angle 90° Following the tightening order, loosen the bolt one by one, and then retighten it to the specific torque.
Page 395 CLUTCH Removing the pull lever shaft 10 Nm (1.0 m kgf, 7.2 ft lbf) • • Order Job/Parts to remove Q’ty Remarks Circlip Pull lever Pull lever spring Circlip Pull lever shaft Oil seal Bearing Bearing Clutch cover damper plate Clutch cover damper 5-54...
Page 396 CLUTCH Removing the clutch 125 Nm (12.5 m kgf, 90 ft lbf) • • 10 Nm (1.0 m kgf, 7.2 ft lbf) • • Order Job/Parts to remove Q’ty Remarks Pressure plate 1 Compression spring Pressure plate 2 Pull rod Bearing Press the bearing into pressure plate 2.
Page 397 CLUTCH • Friction plates 2 EAS30346 REMOVING THE CLUTCH • Clutch damper spring 1. Remove: • Clutch damper spring seat • Clutch cover “1” • Gasket Loosen each bolt 1/4 of a turn at a time, in stag- es and in a crisscross pattern. After all of the bolts are fully loosened, remove them.
Page 398 CLUTCH • Thrust plate Clutch plate 1 thickness • Clutch housing assembly 2.46–2.74 mm (0.097–0.108 in) • Bearing Warpage limit • Washer 0.10 mm (0.004 in) Clutch plate 2 thickness EAS30348 2.18–2.42 mm (0.086–0.095 in) CHECKING THE FRICTION PLATES Warpage limit The following procedure applies to all of the fric- 0.10 mm (0.004 in) tion plates.
Page 399 CLUTCH housing dogs or replace the clutch housing. Clutch plate “1” Pitting on the clutch housing dogs will cause er- Part No. Thickness ratic clutch operation. 2CR-16325-10 2.0 mm (0.079 in) 2CR-16325-00 2.3 mm (0.091 in) 2CR-16325-20 2.6 mm (0.102 in) 2.
Page 400 CLUTCH 2. Check: EAS30356 CHECKING THE PRIMARY DRIVE GEAR • Pull rod bearing 1. Check: Damage/wear Replace. • Primary drive gear EAS30363 Damage/wear Replace the crankshaft and INSTALLING THE CLUTCH clutch housing as a set. Excessive noise during operation Replace After assembling the clutch assembly, the noise the crankshaft and clutch housing as a set.
Page 401 CLUTCH 2. Install: 3. Lubricate: • Thrust plate • Friction plates • Clutch boss “1” • Clutch plates • Conical spring washer “2” (with the recommended lubricant) • Clutch boss nut “3” Recommended lubricant Engine oil Clutch boss nut 125 Nm (12.5 m·kgf, 90 ft·lbf) 4.
Page 402 CLUTCH • Tighten the clutch spring bolts in stages and in a crisscross pattern. • Apply lithium-soap-based grease onto the pull rod. • Position the pull rod so that the teeth “a” face towards the rear of the vehicle. Then, install the clutch cover.
Page 403 SHIFT SHAFT EAS20057 SHIFT SHAFT Removing the shift shaft and stopper lever 22 Nm (2.2 m kgf, 16 ft lbf) • • Order Job/Parts to remove Q’ty Remarks Clutch assembly Refer to “CLUTCH” on page 5-53. Shift arm Refer to “CHAIN DRIVE” on page 4-116. Circlip Washer Shift shaft...
Page 404: Shift Shaft
SHIFT SHAFT ment assembly. EAS30377 CHECKING THE SHIFT SHAFT 1. Check: • Shift shaft “1” Bends/damage/wear Replace. • Shift shaft spring “2” • Collar Damage/wear Replace. 2. Install: • Bearing • Oil seal • Washer “1” • Circlip “2” • Lubricate the oil seal lips with lithium-soap- EAS30378 CHECKING THE STOPPER LEVER based grease.
Page 405 CRANKCASE EAS20059 CRANKCASE Removing the crankcase breather cover and switches 6 Nm (0.6 m kgf, 4.3 ft Ibf) 12 Nm (1.2 m kgf, 8.7 ft lbf) • • • • 3.0 Nm (0.30 m kgf, 2.2 ft Ibf) • • Specified angle 90°...
Page 406 CRANKCASE Removing the crankcase breather cover and switches 6 Nm (0.6 m kgf, 4.3 ft Ibf) 12 Nm (1.2 m kgf, 8.7 ft lbf) • • • • 3.0 Nm (0.30 m kgf, 2.2 ft Ibf) • • Specified angle 90° 17 Nm (1.7 m kgf, 12 ft lbf)
Page 407 CRANKCASE Separating the crankcase 10 Nm (1.0 m kgf, 7.2 ft lbf) 20 Nm (2.0 m kgf, 14 ft lbf) • • • • 15 Nm (1.5 m kgf, 11 ft lbf) • • 24 Nm (2.4 m kgf, 17 ft lbf) •...
Page 408 Recommended lubricant Engine oil 2. Apply: • Sealant (onto the crankcase mating surfaces) Yamaha bond No. 1215 90890-85505 (Three bond No.1215®) Do not allow any sealant to come into contact with the oil gallery or crankshaft journal bear- ings, or balancer shaft journal bearings.
Page 409 CRANKCASE 4. Set the shift drum assembly and transmission gears in the neutral position. 5. Install: • Lower crankcase “1” (onto the upper crankcase “2”) ECA13980 NOTICE Before tightening the crankcase bolts, make sure the transmission gears shift correctly when the shift drum assembly is turned by hand.
Page 410 CRANKCASE EAS31718 INSTALLING THE CRANKCASE BREATHER COVER 1. Install: • Crankcase breather cover • Crankcase breather cover bolt 2. Tighten: • Crankcase breather cover bolt Crankcase breather cover bolt 1st: 6 Nm (0.6 m·kgf, 4.3 ft·lbf) *2nd: 3.0 Nm (0.30 m·kgf, 2.2 ft·lbf) Specified angle 90 Following the tightening order, loosen the bolt...
Page 411 CRANKCASE 53˚ EAS31658 INSTALLING THE GEAR POSITION SENSOR ECA22630 NOTICE To prevent damage to the gear position sen- sor, keep magnets (including any pickup tool with a magnet, magnetized screwdrivers, etc.) away from the gear position sensor. 1. Install: • O-ring •...
Page 412 CONNECTING RODS AND PISTONS EAS20132 CONNECTING RODS AND PISTONS Removing the connecting rods and pistons 25 Nm (2.5 m kgf, 18 ft lbf) • • Specified angle 180˚ Order Job/Parts to remove Q’ty Remarks Lower crankcase Refer to “CRANKCASE” on page 5-64. Connecting rod cap Big end lower bearing Big end upper bearing...
Page 413 CONNECTING RODS AND PISTONS EAS30745 REMOVING THE CONNECTING RODS AND PISTONS The following procedure applies to all of the con- necting rods and pistons. 1. Remove: • Connecting rod cap “1” • Connecting rod • Big end bearings • Identify the position of each big end bearing so that it can be reinstalled in its original place.
Page 414 CONNECTING RODS AND PISTONS pin is still difficult to remove, remove it with the piston pin puller set “3”. Piston pin puller set 90890-01304 Piston pin puller YU-01304 d. Remove the piston pin clip “1” using long- nose pliers or a similar tool. When removing the piston pin clip, hold the pis- ton pin clip in place with your fingers because it can easily spring.
Page 415 CONNECTING RODS AND PISTONS block, and replace the pistons and piston rings as a set. 2. Measure: • Piston-to-cylinder clearance ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Measure cylinder bore “C” with the cylinder bore gauge. Measure cylinder bore “C” by taking side-to-side and front-to-back measurements of the cylinder. Then, find the average of the measurements.
Page 416 CONNECTING RODS AND PISTONS EAS30749 CHECKING THE PISTON PIN The following procedure applies to all of the pis- ton pins. 1. Measure: • Piston pin outside diameter “a” Out of specification Replace the piston pin. Piston pin outside diameter 16.991–17.000 mm (0.6689– 0.6693 in) Limit 2.
Page 417 CONNECTING RODS AND PISTONS with the notches “b” in the connecting rod and Piston-pin-to-piston-pin-bore connecting rod cap. clearance 0.002–0.022 mm (0.0001–0.0009 Limit 0.072 mm (0.0028 in) EAS30750 CHECKING THE CONNECTING RODS 1. Measure: • Crankshaft-pin-to-big-end-bearing clearance Out of specification Replace the big end bearings.
Page 418 CONNECTING RODS AND PISTONS Install by carrying out the following procedures in order to assemble in the most suitable condition. f. Tighten the connecting rod bolt while check- ing that the sections shown “a” and “b” are flush with each other by touching the surface. Connecting rod bolt 30 Nm (3.0 m·kgf, 22 ft·lbf) To install the connecting rod cap, care should be...
Page 419 CONNECTING RODS AND PISTONS web and the numbers “1” on the connecting rods are used to determine the replacement big end bearings sizes. • “P ”–“P ” refer to the bearings shown in the crankshaft illustration. For example, if the connecting rod “P ”...
Page 420 CONNECTING RODS AND PISTONS 1. Install: 2. Tighten: • Big end bearings • Connecting rod bolts • Connecting rod cap ECA18390 NOTICE (onto the connecting rod) Tighten the connecting rod bolts using the plastic-region tightening angle method. Al- • Clean the big end bearings, crankshaft pins, ways install new bolts.
Page 421 CONNECTING RODS AND PISTONS • 2nd ring “4” • Top ring “5” (into the piston) Be sure to install the piston rings so that the manufacturer’s marks or numbers “a” face up. Align the piston pin clip end with the position “a”. 4.
Page 422 CONNECTING RODS AND PISTONS d. Make sure the piston pin clip “1” is positioned ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ as shown in the illustration. 6. Lubricate: • Piston • Piston rings • Cylinder (with the recommended lubricant) Recommended lubricant Engine oil 7. Offset: • Piston ring end gaps e.
Page 423 CONNECTING RODS AND PISTONS stall the piston assembly into the cylinder from ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ underneath. • Install the piston assembly into the cylinder so Tighten the connecting rod bolts using the fol- that the piston ring end gap is aligned with the lowing procedure.
Page 424 CONNECTING RODS AND PISTONS EWA17120 WARNING If the connecting rod and cap are not flush with each other, remove the connecting rod bolts and big end bearing and restart from step (1). In this case, make sure to replace the connecting rod bolts. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲...
Page 425 CRANKSHAFT AND BALANCER SHAFT EAS20178 CRANKSHAFT AND BALANCER SHAFT Removing the crankshaft and balancer shaft 3.0 Nm (0.30 m kgf, 2.2 ft lbf) • • 10 Nm (1.0 m kgf, 7.2 ft lbf) • • Order Job/Parts to remove Q’ty Remarks Lower crankcase Refer to “CRANKCASE”...
Page 426 CRANKSHAFT AND BALANCER SHAFT EAS31171 REMOVING THE CRANKSHAFT AND BALANCER SHAFT 1. Remove: • Balancer shaft “1” • Balancer shaft journal bearing • Crankshaft assembly “2” • Crankshaft journal bearings Identify the position of each balancer shaft jour- nal bearings and crankshaft journal bearings so 2.
Page 427 CRANKSHAFT AND BALANCER SHAFT If the crankshaft-journal-to-crankshaft-jour- nal-bearing clearance is out of specification, select replacement crankshaft journal bear- ings. d. Put a piece of Plastigauge® “1” on each crankshaft journal. Do not put the Plastigauge® over the oil hole in the crankshaft journal.
Page 428 CRANKSHAFT AND BALANCER SHAFT Balancer shaft journal to balancer shaft bearing clearance 0.028–0.046 mm (0.0011–0.0018 ECA18400 NOTICE Do not interchange the balancer shaft jour- nal bearings. To obtain the correct balancer shaft-journal-to-balancer shaft-journal-bear- ing clearance and prevent engine damage, the balancer shaft journal bearings must be installed in their original positions.
Page 429 CRANKSHAFT AND BALANCER SHAFT • If “J e. Install the balancer shaft journal lower bear- ”–“J ” are the same, use the same size for ings “1” into the lower crankcase and assem- all of the bearings. ble the crankcase halves. For example, if the crankcase “J ”...
Page 430 CRANKSHAFT AND BALANCER SHAFT • Align the projections “a” on the crankshaft jour- nal bearings “1” with the notches “b” in the crankcase. • Be sure to install each crankshaft journal bear- ings in its original place. EAS31172 INSTALLING THE BALANCER ASSEMBLY 1.
Page 431 TRANSMISSION EAS20062 TRANSMISSION Removing the transmission, shift drum assembly, and shift forks 12 Nm (1.2 m kgf, 8.7 ft lbf) • • 10 Nm (1.0 m kgf, 7.2 ft lbf) • • 10 Nm (1.0 m kgf, 7.2 ft lbf) •...
Page 432 TRANSMISSION Disassembling the main axle assembly Order Job/Parts to remove Q’ty Remarks 2nd pinion gear Toothed lock washer Toothed lock washer retainer 6th pinion gear Collar Washer Circlip 3rd pinion gear Circlip Washer 5th pinion gear Collar Bearing housing Bearing Main axle 5-91...
Page 433 TRANSMISSION Disassembling the drive axle assembly Order Job/Parts to remove Q’ty Remarks Circlip Bearing Washer 1st wheel gear Collar 5th wheel gear Circlip Washer 3rd wheel gear Collar Toothed lock washer Toothed lock washer retainer 4th wheel gear Collar Washer Circlip 6th wheel gear Circlip...
Page 434 TRANSMISSION Disassembling the drive axle assembly Order Job/Parts to remove Q’ty Remarks Washer 2nd wheel gear Collar Collar Oil seal Circlip Bearing Drive axle 5-93...
Page 435 TRANSMISSION EAS30430 REMOVING THE TRANSMISSION 1. Remove: • Drive axle assembly “1” • Shift drum retainers “2” • Shift fork guide bars • Shift fork-L • Shift fork-R • Shift drum assembly • Shift fork-C EAS30431 CHECKING THE SHIFT FORKS The following procedure applies to all of the shift forks.
Page 436 TRANSMISSION Out of specification Replace the drive axle. Drive axle runout limit 0.08 mm (0.0032 in) EAS30432 CHECKING THE SHIFT DRUM ASSEMBLY 1. Check: • Shift drum groove Damage/scratches/wear Replace the shift drum assembly. • Shift drum segment “1” 3. Check: Damage/wear Replace the shift drum as- •...
Page 437 TRANSMISSION • Be sure the circlip sharp-edged corner “a” is positioned opposite side to the toothed washer and gear. • Install the circlip so that a spline “b” is in the center of the gap between the circlip ends “c” as shown.
Page 438 TRANSMISSION 3. Install: • Shift fork-C “1” • Shift drum assembly “2” • Shift fork guide bar “3” • The embossed marks on the shift forks should face towards the right side of the engine and be in the following sequence: “R”, “C”, “L”. •...
Page 439 COOLING SYSTEM RADIATOR......................6-1 REMOVING THE RADIATOR ..............6-2 CHECKING THE RADIATOR..............6-2 INSTALLING THE RADIATOR..............6-3 OIL COOLER....................6-4 CHECKING THE OIL COOLER ..............6-5 INSTALLING THE OIL COOLER ...............6-5 THERMOSTAT....................6-6 REMOVING THE THERMOSTAT ASSEMBLY..........6-7 CHECKING THE THERMOSTAT...............6-7 ASSEMBLING THE THERMOSTAT ASSEMBLY........6-7 INSTALLING THE THERMOSTAT ASSEMBLY ........6-7 WATER PUMP ....................6-9 DISASSEMBLING THE WATER PUMP...........6-11 CHECKING THE WATER PUMP .............6-11...
Page 440 RADIATOR EAS20063 RADIATOR Removing the radiator 8 Nm (0.8 m kgf, 5.8 ft Ibf) • • 8 Nm (0.8 m kgf, 5.8 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft lbf) •...
Page 441 RADIATOR EAS31659 REMOVING THE RADIATOR 1. Remove: • Hose clamp (Clic-R) “1” • Remove the hose clamp using the hose clamp pliers “2”. • When removing the hose clamp, make sure that the thick tip “a” of the hose clamp pliers is directed as shown in the illustration.
Page 442 RADIATOR EAS30440 INSTALLING THE RADIATOR Radiator cap tester 90890-01325 1. Install: Mityvac cooling system tester kit • Radiator YU-24460-A 2. Connect: Radiator cap tester adapter • Radiator inlet hose 90890-01352 • Radiator outlet hose Pressure tester adapter 3. Install: YU-33984 •...
Page 443 OIL COOLER EAS20064 OIL COOLER Removing the oil cooler 10 Nm (1.0 m kgf, 7.2 ft lbf) • • 10 Nm (1.0 m kgf, 7.2 ft lbf) • • 10 Nm (1.0 m kgf, 7.2 ft lbf) • • 10 Nm (1.0 m kgf, 7.2 ft lbf) •...
Page 444 OIL COOLER EAS30441 CHECKING THE OIL COOLER 1. Check: • Oil cooler Cracks/damage Replace. • Oil cooler fins Obstruction Clean. Apply compressed air to the rear of the oil cooler. Damage Repair or replace. Straighten any flattened fins with a thin, flat-head screwdriver.
Page 445 THERMOSTAT EAS20065 THERMOSTAT Removing the thermostat 10 Nm (1.0 m kgf, 7.2 ft lbf) • • 10 Nm (1.0 m kgf, 7.2 ft lbf) • • 10 Nm (1.0 m kgf, 7.2 ft lbf) • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS (1)”...
Page 446 THERMOSTAT EAS31660 REMOVING THE THERMOSTAT ASSEMBLY 1. Remove: • Hose clamp (Clic-R) Refer to “REMOVING THE RADIATOR” on page 6-2. • Radiator inlet hose 2. Remove: • Thermostat assembly 159.8 EAS30443 CHECKING THE THERMOSTAT A. Fully closed 1. Check: B. Fully open •...
Page 447 THERMOSTAT 2. Install: • Radiator inlet hose • Hose clamp (Clic-R) Refer to “INSTALLING THE RADIATOR” on page 6-3. For more information about installing the hose, refer to “CABLE ROUTING” on page 2-51. 3. Fill: • Cooling system (with the specified amount of the recom- mended coolant) Refer to “CHANGING THE COOLANT”...
Page 448 WATER PUMP EAS20066 WATER PUMP Removing the water pump 10 Nm (1.0 m kgf, 7.2 ft lbf) • • 10 Nm (1.0 m kgf, 7.2 ft lbf) • • 10 Nm (1.0 m kgf, 7.2 ft lbf) • • 10 Nm (1.0 m kgf, 7.2 ft lbf) 10 Nm (1.0 m...
Page 449 WATER PUMP Disassembling the water pump 10 Nm (1.0 m kgf, 7.2 ft lbf) • • 10 Nm (1.0 m kgf, 7.2 ft lbf) • • Order Job/Parts to remove Q’ty Remarks Water pump housing cover O-ring Circlip Impeller shaft Mechanical seal Bearing Oil seal...
Page 450 WATER PUMP EAS30446 EAS30447 DISASSEMBLING THE WATER PUMP CHECKING THE WATER PUMP 1. Remove: 1. Check: • Mechanical seal (housing side) “1” • Water pump housing cover “1” • Impeller shaft “2” Cracks/damage/wear Replace. Remove the mechanical seal (housing side) •...
Page 451 WATER PUMP 4. Measure: ECA20330 NOTICE • Impeller shaft tilt Never lubricate the mechanical seal (hous- Out of specification Repeat steps (3) and ing side) surface with oil or grease. (4). ECA20340 NOTICE Use the special tools and a press to press the Make sure the mechanical seal (impeller mechanical seal (housing side) straight in until it side) is flush with the impeller.
Page 452 WATER PUMP 4. Measure: • Radiator cap opening pressure Below the specified pressure Replace the radiator cap. Refer to “CHECKING THE RADIATOR” on page 6-2. 6-13...
Page 453 FUEL SYSTEM FUEL TANK ......................7-1 REMOVING THE FUEL TANK ..............7-2 REMOVING THE FUEL PUMP ..............7-2 CHECKING THE FUEL PUMP BODY............7-2 CHECKING THE FUEL PUMP OPERATION..........7-2 INSTALLING THE FUEL PUMP..............7-3 INSTALLING THE FUEL TANK..............7-3 AIR FILTER CASE....................7-4 CHECKING THE SECONDARY INJECTORS (BEFORE REMOVING) ..7-5 REMOVING THE FUEL HOSE (PRIMARY INJECTOR JOINT SIDE AND SECONDARY INJECTOR JOINT SIDE) ..........7-5 REMOVING THE SECONDARY INJECTORS...........7-5...
Page 454 FUEL TANK EAS20067 FUEL TANK Removing the fuel tank 4.0 Nm (0.40 m kgf, 2.9 ft lbf) • • 4.0 Nm (0.40 m kgf, 2.9 ft lbf) • • 4.0 Nm (0.40 m kgf, 2.9 ft lbf) • • 6 Nm (0.6 m kgf, 4.3 ft Ibf) •...
Page 455: Fuel Tank
FUEL TANK EAS30450 REMOVING THE FUEL TANK 1. Extract the fuel in the fuel tank through the fuel tank cap with a pump. 2. Remove: • Rider seat Refer to “GENERAL CHASSIS (1)” on page 4-1. • Fuel tank cover Refer to “GENERAL CHASSIS (2)”...
Page 456 FUEL TANK EAS30456 INSTALLING THE FUEL PUMP • Install the fuel hose onto the fuel pump secure- 1. Install: ly, and slide the fuel hose connector cover “1” • Fuel pump gasket in the direction shown in the illustration. • Fuel pump •...
Page 457 AIR FILTER CASE EAS20068 AIR FILTER CASE Removing the air filter case and secondary injectors 3.5 Nm (0.35 m kgf, 2.5 ft lbf) • • 8 Nm (0.8 m kgf, 5.8 ft Ibf) • • (10) 3.5 Nm (0.35 m kgf, 2.5 ft lbf) •...
Page 458 AIR FILTER CASE that there is no smoking or use of electric EAS30458 CHECKING THE SECONDARY INJECTORS tools in the vicinity of the injectors. (BEFORE REMOVING) • Be careful when disconnecting the fuel 1. Check: hose. Any remaining pressure in the fuel •...
Page 459 AIR FILTER CASE 3. Disconnect: ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ • Crankcase breather hose • Air induction system hose EAS30462 CHECKING THE SECONDARY INJECTORS • Intake funnel servo motor coupler 1. Check: 4. Remove: • Injectors • Air filter case Obstruction Replace and check the fuel pump/fuel supply system.
Page 460 AIR FILTER CASE should not make any unusual sound. ECA17550 NOTICE • Make sure that the intake funnel smoothly moves to the contacting surface between upper stopper and lower seating position when it is moved by hand. • Make sure that the intake funnel smoothly strokes from the upper position to the seat- ing position by its own weight.
Page 461 AIR FILTER CASE hose connector cover on the fuel hose is in the correct position, otherwise the fuel hose will not be properly installed. • Install the fuel hose securely onto the second- ary injector joint until a distinct “click” is heard. •...
Page 462 THROTTLE BODIES EAS20070 THROTTLE BODIES Removing the throttle bodies 10 Nm (1.0 m kgf, 7.2 ft lbf) • • 3.0 Nm (0.30 m kgf, 2.2 ft lbf) • • 4.5 Nm (0.45 m kgf, 3.3 ft lbf) • • 23 Nm (2.3 m kgf, 17 ft lbf) •...
Page 463 THROTTLE BODIES Removing the throttle bodies 10 Nm (1.0 m kgf, 7.2 ft lbf) • • 3.0 Nm (0.30 m kgf, 2.2 ft lbf) • • 4.5 Nm (0.45 m kgf, 3.3 ft lbf) • • 23 Nm (2.3 m kgf, 17 ft lbf) •...
Page 464 THROTTLE BODIES Removing the sensors 3.5 Nm (0.35 m kgf, 2.5 ft lbf) • • 3.5 Nm (0.35 m kgf, 2.5 ft lbf) • • 3.5 Nm (0.35 m kgf, 2.5 ft lbf) • • 3.5 Nm (0.35 m kgf, 2.5 ft lbf) •...
Page 465 Replace and check the fuel erwise, the throttle body synchronization pump/fuel supply system. will be affected. Deposit Replace. Damage Replace. Recommended cleaning solvent 2. Check: Yamaha Oil & Brake Cleaner • Injector resistance Refer to “CHECKING THE FUEL INJEC- 7-12...
Page 466 THROTTLE BODIES • Do not allow any cleaning solvent to enter the opening for the injectors. • Do not apply any cleaning solvent to the por- tions of the throttle valve shafts between the throttle bodies. e. Remove the carbon deposits from the inside of each throttle body in a downward direction, from the air filter case side of the throttle body to the engine side.
Page 467 THROTTLE BODIES bodies. Fuel rail screw (throttle body) Refer to “SYNCHRONIZING THE THROT- 3.5 Nm (0.35 m·kgf, 2.5 ft·lbf) TLE BODIES” on page 3-9. EAS31160 REPLACING THE THROTTLE BODIES 1. Remove the throttle bodies from the vehicle. 2. Install a new throttle bodies to the vehicle. 3.
Page 468 THROTTLE BODIES tools. c. Close the valve on the injector pressure adapter. d. Apply air pressure with the air compressor. e. Open the valve on the injector pressure adapter until the specified pressure is reached. Specified air pressure 490 kPa (5.0 kgf/cm², 71.1 psi) ECA17600 NOTICE Never exceed the specified air pressure or...
Page 469 THROTTLE BODIES f. Press the up button “1” or down button “4” to EAS30485 ADJUSTING THE THROTTLE POSITION select ECU in the display, and then simulta- SENSOR neously press the up button “1” and center EWA16690 button “2” for 2 seconds or more. WARNING •...
Page 470 THROTTLE BODIES h. Diagnostic code number “01” is selected. to “ON”, and continue to press the buttons for i. Adjust the position of the throttle position sen- 8 seconds more. sor angle so that 11–21 can appear in the meter right display. “ECU”...
Page 471 THROTTLE BODIES center button “2” for 2 seconds or more. o. Select the diagnostic code number “15”. p. Turn the throttle grip to the fully closed posi- The diagnostic code number “01” appears on tion. q. Check the meter display value. If the meter the display.
Page 472: Air Induction System
AIR INDUCTION SYSTEM EAS20071 AIR INDUCTION SYSTEM 7-19...
Page 473 AIR INDUCTION SYSTEM 1. Air filter case 2. Air cut-off valve 3. Air induction system hose (air filter case to air cut-off valve) 4. Cylinder head cover 5. Air induction system hose (air cut-off valve to reed valve cover) 7-20...
Page 474 AIR INDUCTION SYSTEM Removing the air cut-off valve assembly and reed valves 9 Nm (0.9 m kgf, 6.5 ft lbf) 0.3 Nm (0.03 m kgf, 0.22 ft lbf) • • • • 10 Nm (1.0 m kgf, 7.2 ft lbf) •...
Page 475 AIR INDUCTION SYSTEM Removing the air cut-off valve assembly and reed valves 9 Nm (0.9 m kgf, 6.5 ft lbf) 0.3 Nm (0.03 m kgf, 0.22 ft lbf) • • • • 10 Nm (1.0 m kgf, 7.2 ft lbf) •...
Page 476 AIR INDUCTION SYSTEM EAS30488 CHECKING THE AIR INDUCTION SYSTEM Air injection The air induction system burns unburned ex- haust 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, allow- ing secondary air to flow into the exhaust port.
Page 477 AIR INDUCTION SYSTEM 3. Install: • Reed valve cover Reed valve cover bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) LOCTITE® 4. Check: • Air cut-off valve Cracks/damage Replace. 5. Check: • Air induction system solenoid Refer to “CHECKING THE AIR INDUCTION SYSTEM SOLENOID”...
Page 478 AIR INDUCTION SYSTEM 7-25...
Page 479: General Information
CIRCUIT DIAGRAM .................8-39 TROUBLESHOOTING ................8-43 FUEL INJECTION SYSTEM................8-45 CIRCUIT DIAGRAM .................8-45 ECU SELF-DIAGNOSTIC FUNCTION.............8-49 TROUBLESHOOTING METHOD (ECU)..........8-50 DIAGNOSTIC MODE (ECU) ..............8-51 YAMAHA DIAGNOSTIC TOOL ..............8-52 TROUBLESHOOTING DETAILS (ECU) ..........8-54 FUEL PUMP SYSTEM..................8-103 CIRCUIT DIAGRAM ................8-103 TROUBLESHOOTING ................8-107 IMMOBILIZER SYSTEM................8-109 CIRCUIT DIAGRAM ................8-109 GENERAL INFORMATION ..............8-113...
Page 480 ABS (Anti-lock Brake System) ..............8-119 CIRCUIT DIAGRAM ................8-119 ABS COMPONENTS CHART ..............8-123 ABS COUPLER LOCATION CHART .............8-125 MAINTENANCE OF THE ABS ECU ............8-127 ABS TROUBLESHOOTING OUTLINE...........8-127 BASIC INSTRUCTIONS FOR TROUBLESHOOTING ......8-128 BASIC PROCESS FOR TROUBLESHOOTING ........8-129 [A] CHECKING THE ABS WARNING LIGHT.........8-130 [A-1] ONLY THE ABS WARNING LIGHT FAILS TO COME ON....8-130 [A-2] THE ABS WARNING LIGHT AND OTHER INDICATOR LIGHTS FAIL TO COME ON ..............8-130...
Page 481 CHECKING THE THROTTLE POSITION SENSOR ......8-191 CHECKING THE ACCELERATOR POSITION SENSOR ......8-191 CHECKING THE THROTTLE SERVO MOTOR ........8-192 CHECKING THE AIR INDUCTION SYSTEM SOLENOID .....8-192 CHECKING THE ATMOSPHERIC PRESSURE SENSOR ....8-193 CHECKING THE CYLINDER IDENTIFICATION SENSOR ....8-193 CHECKING THE INTAKE AIR PRESSURE SENSOR ......8-194 CHECKING THE INTAKE AIR TEMPERATURE SENSOR ....8-194 CHECKING THE INTAKE SOLENOID...........8-195 CHECKING THE STEERING DAMPER SOLENOID ......8-195...
Page 482 IGNITION SYSTEM EAS20072 IGNITION SYSTEM EAS30490 CIRCUIT DIAGRAM For YZF-R1...
Page 483 IGNITION SYSTEM 3. Main switch 4. Main fuse 9. Backup fuse 12.Ignition fuse 18.Joint coupler 19.Battery 20.Engine ground 25.Handlebar switch (right) 28.Start/engine stop switch 29.Relay unit 32.Neutral switch 33.Sidestand switch 37.ECU (Engine Control Unit) 38.Ignition coil #1 39.Ignition coil #2 40.Ignition coil #3 41.Ignition coil #4 42.Spark plug...
Page 484: Ignition System
IGNITION SYSTEM For YZF-R1M...
Page 485 IGNITION SYSTEM 3. Main switch 4. Main fuse 9. Backup fuse 12.Ignition fuse 18.Joint coupler 19.Battery 20.Engine ground 25.Handlebar switch (right) 28.Start/engine stop switch 29.Relay unit 32.Neutral switch 33.Sidestand switch 37.ECU (Engine Control Unit) 38.Ignition coil #1 39.Ignition coil #2 40.Ignition coil #3 41.Ignition coil #4 42.Spark plug...
Page 486 IGNITION SYSTEM EAS30491 ENGINE STOPPING DUE TO SIDESTAND OPERATION When the engine is running and the transmission is in gear, the engine will stop if the sidestand is moved down. This is because the electric current from the ECU does not flow to the ignition coils or fuel injectors when the neutral switch or sidestand switch is open.
Page 487 IGNITION SYSTEM EAS30492 TROUBLESHOOTING The ignition system fails to operate (no spark or intermittent spark). • Before troubleshooting, remove the following part(s): 1. Front side cowling/Front panel 2. Rider seat 3. Fuel tank cover 4. Fuel tank 5. Air filter case 1.
Page 488 IGNITION SYSTEM 9. Check the start/engine stop switch. Refer to “CHECKING THE Replace the right handlebar switch. SWITCHES” on page 8-177. 10.Check the neutral switch. Refer to “CHECKING THE Replace the neutral switch. SWITCHES” on page 8-177. 11.Check the sidestand switch. Refer to “CHECKING THE Replace the sidestand switch.
Page 489 IGNITION SYSTEM...
Page 490 ELECTRIC STARTING SYSTEM EAS20073 ELECTRIC STARTING SYSTEM EAS30493 CIRCUIT DIAGRAM For YZF-R1...
Page 491 ELECTRIC STARTING SYSTEM 3. Main switch 4. Main fuse 9. Backup fuse 12.Ignition fuse 18.Joint coupler 19.Battery 20.Engine ground 22.Starter relay 23.Starter motor 25.Handlebar switch (right) 28.Start/engine stop switch 29.Relay unit 30.Starting circuit cut-off relay 32.Neutral switch 33.Sidestand switch 37.ECU (Engine Control Unit) 60.Joint connector 91.Handlebar switch (left) 97.Clutch switch...
Page 492 ELECTRIC STARTING SYSTEM For YZF-R1M 8-11...
Page 493 ELECTRIC STARTING SYSTEM 3. Main switch 4. Main fuse 9. Backup fuse 12.Ignition fuse 18.Joint coupler 19.Battery 20.Engine ground 22.Starter relay 23.Starter motor 25.Handlebar switch (right) 28.Start/engine stop switch 29.Relay unit 30.Starting circuit cut-off relay 32.Neutral switch 33.Sidestand switch 37.ECU (Engine Control Unit) 60.Joint connector 91.Handlebar switch (left) 97.Clutch switch...
Page 494 ELECTRIC STARTING SYSTEM EAS30494 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION If the main switch is turned to “ON” and the “ ” side of the start/engine stop switch is pushed, the starter motor can only operate if at least one of the following conditions is met: •...
Page 495 ELECTRIC STARTING SYSTEM EAS30495 TROUBLESHOOTING The starter motor fails to turn. • Before troubleshooting, remove the following part(s): 1. Front side cowling/Front panel/Side cover 2. Rider seat 3. Fuel tank cover 4. Fuel tank 5. Air filter case 6. Throttle bodies 1.
Page 496 ELECTRIC STARTING SYSTEM 9. Check the neutral switch. Refer to “CHECKING THE Replace the neutral switch. SWITCHES” on page 8-177. 10.Check the sidestand switch. Refer to “CHECKING THE Replace the sidestand switch. SWITCHES” on page 8-177. 11.Check the clutch switch. Refer to “CHECKING THE Replace the clutch switch.
Page 497 ELECTRIC STARTING SYSTEM 8-16...
Page 498 CHARGING SYSTEM EAS20074 CHARGING SYSTEM EAS30496 CIRCUIT DIAGRAM For YZF-R1 8-17...
Page 499 CHARGING SYSTEM 1. AC magneto 2. Rectifier/regulator 4. Main fuse 19.Battery 20.Engine ground 8-18...
Page 500 CHARGING SYSTEM For YZF-R1M 8-19...
Page 501 CHARGING SYSTEM 1. AC magneto 2. Rectifier/regulator 4. Main fuse 19.Battery 20.Engine ground 8-20...
Page 502 CHARGING SYSTEM EAS30497 TROUBLESHOOTING The battery is not being charged. • Before troubleshooting, remove the following part(s): 1. Front side cowling/Front panel/Side cover bracket/Electrical components tray 2. Rider seat 1. Check the fuse. (Main) Replace the fuse. Refer to “CHECKING THE FUSES” on page 8-180.
Page 503 CHARGING SYSTEM 8-22...
Page 504 LIGHTING SYSTEM EAS20075 LIGHTING SYSTEM EAS30498 CIRCUIT DIAGRAM For YZF-R1 8-23...
Page 505 LIGHTING SYSTEM 3. Main switch 4. Main fuse 9. Backup fuse 12.Ignition fuse 13.Signaling system fuse 16.Headlight fuse 18.Joint coupler 19.Battery 20.Engine ground 37.ECU (Engine Control Unit) 60.Joint connector 76.Meter assembly 81.Multi-function meter 86.Meter light 88.High beam indicator light 91.Handlebar switch (left) 93.Pass/LAP switch 94.Dimmer switch 104.Headlight control unit...
Page 506 LIGHTING SYSTEM For YZF-R1M 8-25...
Page 507 LIGHTING SYSTEM 3. Main switch 4. Main fuse 9. Backup fuse 12.Ignition fuse 13.Signaling system fuse 16.Headlight fuse 18.Joint coupler 19.Battery 20.Engine ground 37.ECU (Engine Control Unit) 60.Joint connector 76.Meter assembly 81.Multi-function meter 86.Meter light 88.High beam indicator light 91.Handlebar switch (left) 93.Pass/LAP switch 94.Dimmer switch 104.Headlight control unit...
Page 508 LIGHTING SYSTEM EAS30499 TROUBLESHOOTING Any of the following fail to light: headlight, auxiliary light, high beam indicator light, tail/brake light, li- cense plate light or meter light. • Before troubleshooting, remove the following part(s): 1. Front side cowling/Front panel/Side cover 2.
Page 509 LIGHTING SYSTEM 8-28...
Page 510 SIGNALING SYSTEM EAS20076 SIGNALING SYSTEM EAS30500 CIRCUIT DIAGRAM For YZF-R1 8-29...
Page 511 SIGNALING SYSTEM 3. Main switch 4. Main fuse 6. Hazard lighting fuse 9. Backup fuse 12.Ignition fuse 13.Signaling system fuse 14.ABS ECU fuse 18.Joint coupler 19.Battery 20.Engine ground 25.Handlebar switch (right) 26.Front brake light switch 29.Relay unit 32.Neutral switch 34.Fuel sender 36.Shift switch 37.ECU (Engine Control Unit) 57.ABS ECU (Electronic Control Unit)
Page 512 SIGNALING SYSTEM For YZF-R1M 8-31...
Page 513 SIGNALING SYSTEM 3. Main switch 4. Main fuse 6. Hazard lighting fuse 9. Backup fuse 12.Ignition fuse 13.Signaling system fuse 14.ABS ECU fuse 18.Joint coupler 19.Battery 20.Engine ground 25.Handlebar switch (right) 26.Front brake light switch 29.Relay unit 32.Neutral switch 34.Fuel sender 36.Shift switch 37.ECU (Engine Control Unit) 57.ABS ECU (Electronic Control Unit)
Page 514 SIGNALING SYSTEM EAS30501 TROUBLESHOOTING • Any of the following fail to light: turn signal light, brake light or an indicator light. • The horn fails to sound. • The speedometer fails to operate. • Before troubleshooting, remove the following part(s): 1.
Page 515 SIGNALING SYSTEM 2. Check the horn. Refer to “CHECKING THE HORN” Replace the horn. on page 8-189. 3. Check the entire signaling system’s wiring. Properly connect or repair the signaling Refer to “CIRCUIT DIAGRAM” on system’s wiring. page 8-29. This circuit is OK. The tail/brake light fails to come on.
Page 516 SIGNALING SYSTEM The neutral indicator light fails to come on. 1. Check the neutral switch. Refer to “CHECKING THE Replace the neutral switch. SWITCHES” on page 8-177. 2. Check the relay unit (diode). Refer to “CHECKING THE RELAY Replace the relay unit. UNIT (DIODE)”...
Page 517 SIGNALING SYSTEM The fuel level warning light fails to come on. 1. Check the fuel sender. Refer to “CHECKING THE FUEL Replace the fuel pump assembly. SENDER” on page 8-189. 2. Check the entire signaling system’s wiring. Properly connect or repair the signaling Refer to “CIRCUIT DIAGRAM”...
Page 518 SIGNALING SYSTEM 5. Check the shift switch. Refer to “DIAGNOSTIC CODE: SENSOR OPERATION TABLE” on Replace the shift switch. page 9-7 and “CHECKING THE SWITCHES” on page 8-177. 6. Check the neutral switch. Refer to “DIAGNOSTIC CODE: SENSOR OPERATION TABLE” on Replace the neutral switch.
Page 519 SIGNALING SYSTEM 8-38...
Page 520 COOLING SYSTEM EAS20077 COOLING SYSTEM EAS30502 CIRCUIT DIAGRAM For YZF-R1 8-39...
Page 521 COOLING SYSTEM 3. Main switch 4. Main fuse 5. Radiator fan motor relay 9. Backup fuse 10.Radiator fan motor fuse (right) 11.Radiator fan motor fuse (left) 12.Ignition fuse 18.Joint coupler 19.Battery 20.Engine ground 37.ECU (Engine Control Unit) 60.Joint connector 67.Coolant temperature sensor 110.Radiator fan motor (right) 111.Radiator fan motor (left) 8-40...
Page 522 COOLING SYSTEM For YZF-R1M 8-41...
Page 523 COOLING SYSTEM 3. Main switch 4. Main fuse 5. Radiator fan motor relay 9. Backup fuse 10.Radiator fan motor fuse (right) 11.Radiator fan motor fuse (left) 12.Ignition fuse 18.Joint coupler 19.Battery 20.Engine ground 37.ECU (Engine Control Unit) 60.Joint connector 67.Coolant temperature sensor 110.Radiator fan motor (right) 111.Radiator fan motor (left) 8-42...
Page 524 COOLING SYSTEM EAS30503 TROUBLESHOOTING • Before troubleshooting, remove the following part(s): 1. Front side cowling/Front panel/Side cover bracket/Electrical components tray 2. Rider seat 3. Fuel tank cover 4. Fuel tank 5. Air filter case 6. Throttle bodies 1. Check the fuses. (Main, ignition, backup and radiator fan motor) Replace the fuse(s).
Page 525 COOLING SYSTEM 8-44...
Page 526 FUEL INJECTION SYSTEM EAS20078 FUEL INJECTION SYSTEM EAS30504 CIRCUIT DIAGRAM For YZF-R1 8-45...
Page 527 104.Headlight control unit 18.Joint coupler 19.Battery A. Wire harness 20.Engine ground B. Sub-wire harness (intake solenoid) 25.Handlebar switch (right) C. Sub-wire harness (Yamaha diagnostic tool 28.Start/engine stop switch coupler) 29.Relay unit 31.Fuel pump relay 32.Neutral switch 33.Sidestand switch 35.Fuel pump 36.Shift switch...
Page 528 FUEL INJECTION SYSTEM For YZF-R1M 8-47...
Page 529 104.Headlight control unit 18.Joint coupler 19.Battery A. Wire harness 20.Engine ground B. Sub-wire harness (intake solenoid) 25.Handlebar switch (right) C. Sub-wire harness (Yamaha diagnostic tool 28.Start/engine stop switch coupler, CCU, GPS unit) 29.Relay unit 31.Fuel pump relay 32.Neutral switch 33.Sidestand switch 35.Fuel pump...
Page 530 FUEL INJECTION SYSTEM EAS30505 ECU SELF-DIAGNOSTIC FUNCTION The ECU is equipped with a self-diagnostic function in order to ensure that the fuel injection system is operating normally. If this function detects a malfunction in the system, it immediately operates the en- gine under substitute characteristics and illuminates the engine trouble and system warning light to alert the rider that a malfunction has occurred in the system.
Page 531 FUEL INJECTION SYSTEM ECU detects an abnormal signal from a sensor If the ECU detects an abnormal signal from a sensor while the vehicle is being driven, the ECU illumi- nates the engine trouble and system warning light and provides the engine with alternate operating in- structions that are appropriate for the type of malfunction.
Page 532 FUEL INJECTION SYSTEM Setting the main switch to “OFF” will not erase the malfunction history. The engine operation is not normal, but the engine trouble and system warning light does not come on. 1. Check the operation of the following sensors and actuators in the diagnostic mode. Refer to “TROU- BLESHOOTING DETAILS (ECU)”...
Page 533 9. Connect the wire harness coupler to the fuel pump. EAS30951 YAMAHA DIAGNOSTIC TOOL This model uses the Yamaha diagnostic tool to identify malfunctions. For information about using the Yamaha diagnostic tool, refer to the operation manual that is included with the tool. 8-52...
Page 534 Remove the protective cap “1”, and then connect the Yamaha diagnostic tool to the coupler. When the Yamaha diagnostic tool is connected to the vehicle, the operation of the multi-function meter and indicators will be different from the normal operation.
Page 535 FUEL INJECTION SYSTEM EAS30508 TROUBLESHOOTING DETAILS (ECU) This section describes the measures per fault code number displayed on the meter. Check and service the items or components that are the probable cause of the malfunction following the order given. After the check and service of the malfunctioning part have been completed, reset the meter display according to the reinstatement method.
Page 536 FUEL INJECTION SYSTEM Fault code No. Item Gear position sensor: open or short circuit detected. Malfunction in ECU. Replace the ECU. Refer to “REPLACING THE ECU (Engine Control Unit)” on page 8-180. Fault code No. 11 Fault code No. Cylinder identification sensor: no normal signals are received from Item the cylinder identification sensor.
Page 537 FUEL INJECTION SYSTEM Fault code No. Cylinder identification sensor: no normal signals are received from Item the cylinder identification sensor. Defective cylinder identification Check the cylinder identification Crank the engine. sensor. sensor. Fault code number is not dis- Refer to “CHECKING THE CYL- played Service is finished.
Page 538 FUEL INJECTION SYSTEM Fault code No. Crankshaft position sensor: no normal signals are received from Item the crankshaft position sensor. Installed condition of crankshaft Improperly installed sensor Crank the engine. position sensor. Reinstall or replace the sensor. Fault code number is not dis- Check for looseness or pinch- Refer to “GENERATOR”...
Page 539 FUEL INJECTION SYSTEM Fault code No. Item Intake air pressure sensor: open or short circuit detected. Wire harness continuity. Open or short circuit Replace Turn the main switch to “ON”. the wire harness. Fault code number is not dis- Between intake air pressure played Service is finished.
Page 540 FUEL INJECTION SYSTEM Fault code No. 14 Fault code No. Intake air pressure sensor: hose system malfunction (clogged or Item detached hose). Fail-safe system Able to start engine Able to drive vehicle Diagnostic code No. Meter display Displays the intake air pressure. Procedure Operate the throttle while pushing the “...
Page 541 FUEL INJECTION SYSTEM Fault code No. 15 Fault code No. Item Throttle position sensor: open or short circuit detected. Fail-safe system Able/Unable to start engine Able/Unable to drive vehicle Diagnostic code No. 01, 13 Meter display Throttle position sensor signal 1 •...
Page 542 FUEL INJECTION SYSTEM Fault code No. Item Throttle position sensor: open or short circuit detected. Defective throttle position sen- Check throttle position sensor Turn the main switch to “ON”. sor. signal 1. Fault code number is not dis- Execute the diagnostic mode. played Service is finished.
Page 543 FUEL INJECTION SYSTEM Fault code No. Item EXUP servo motor: open or short circuit detected. Connection of wire harness Improperly connected Con- Turn the main switch to “ON”. ECU coupler. nect the coupler securely or Fault code number is not dis- Check the locking condition of replace the wire harness.
Page 544 FUEL INJECTION SYSTEM Fault code No. Item EXUP servo motor: stuck EXUP servo motor is detected. Connection of EXUP servo Improperly connected Con- Turn the main switch to “ON”. motor coupler. nect the coupler securely or Fault code number is not dis- Check the locking condition of replace the wire harness.
Page 545 FUEL INJECTION SYSTEM Fault code No. Sidestand switch: a break or disconnection of the blue/yellow lead Item of the ECU is detected. Item Probable cause of Maintenance job Confirmation of service com- malfunction and check pletion Connection of sidestand switch Improperly connected Con- Turn the main switch to “ON”,...
Page 546 FUEL INJECTION SYSTEM Fault code No. Intake air pressure sensor or atmospheric pressure sensor: when Item the main switch is turned to “ON”, the Intake air pressure sensor voltage and atmospheric pressure sensor voltage differ greatly. Meter display Displays the intake air pressure. Procedure Operate the throttle while pushing the “...
Page 547 FUEL INJECTION SYSTEM Fault code No. 21 Fault code No. Item Coolant temperature sensor: open or short circuit detected. Fail-safe system Able to start engine Able to drive vehicle Diagnostic code No. Meter display Displays the coolant temperature. Procedure Compare the actually measured coolant temperature with the meter dis- play value.
Page 548 FUEL INJECTION SYSTEM Fault code No. Item Coolant temperature sensor: open or short circuit detected. Defective coolant temperature Execute the diagnostic mode. Turn the main switch to “ON”. sensor. (Code No. 06) Fault code number is not dis- When engine is cold: played Service is finished.
Page 549 FUEL INJECTION SYSTEM Fault code No. Item Intake air temperature sensor: open or short circuit detected. Wire harness continuity. Open or short circuit Replace Turn the main switch to “ON”. the wire harness. Fault code number is not dis- Between intake air temperature played Service is finished.
Page 550 FUEL INJECTION SYSTEM Fault code No. Item Atmospheric pressure sensor: open or short circuit detected. Connection of atmospheric Improperly connected Con- Turn the main switch to “ON”. pressure sensor coupler. nect the coupler securely or Fault code number is not dis- Check the locking condition of replace the wire harness.
Page 551 FUEL INJECTION SYSTEM Fault code No. Item Atmospheric pressure sensor: open or short circuit detected. Malfunction in ECU. Replace the ECU. Refer to “REPLACING THE ECU (Engine Control Unit)” on page 8-180. Fault code No. 24 Fault code No. Item sensor 1: no normal signals are received from the O sensor 1.
Page 552 FUEL INJECTION SYSTEM Fault code No. Item sensor 1: no normal signals are received from the O sensor 1. Wire harness continuity. Open or short circuit Replace Start the engine, warm it up, the wire harness. and then race it, or execute the Between O sensor 1 coupler diagnostic mode.
Page 553 FUEL INJECTION SYSTEM Fault code No. Item Latch up detected. The vehicle has overturned. Raise the vehicle upright. Turn the main switch to “ON”, then to “OFF”, and then back to “ON”. Fault code number is not dis- played Service is finished. Fault code number is displayed Go to item 2.
Page 554 FUEL INJECTION SYSTEM Fault code No. Cylinder-#1 ignition coil: open or short circuit detected in the pri- Item mary lead of the cylinder-#1 ignition coil. Connection of wire harness Improperly connected Con- Start the engine and let it idle for ECU coupler.
Page 555 FUEL INJECTION SYSTEM Fault code No. Cylinder-#2 ignition coil: open or short circuit detected in the pri- Item mary lead of the cylinder-#2 ignition coil. Connection of cylinder-#2 igni- Improperly connected Con- Start the engine and let it idle for tion coil coupler.
Page 556 FUEL INJECTION SYSTEM Fault code No. Cylinder-#3 ignition coil: open or short circuit detected in the pri- Item mary lead of the cylinder-#3 ignition coil. Procedure Check that a spark is generated five times. • Connect an ignition checker. Item Probable cause of Maintenance job Confirmation of service com-...
Page 557 FUEL INJECTION SYSTEM Fault code No. Cylinder-#4 ignition coil: open or short circuit detected in the pri- Item mary lead of the cylinder-#4 ignition coil. Diagnostic code No. Actuation Actuates the cylinder-#4 ignition coil five times at one-second intervals. Illuminates the engine trouble and system warning light. Procedure Check that a spark is generated five times.
Page 558 FUEL INJECTION SYSTEM Fault code No. 39 Fault code No. Item Primary injector: open or short circuit detected. Fail-safe system Able to start engine (depending on the number of faulty cylinders) Able to drive vehicle (depending on the number of faulty cylinders) Diagnostic code No.
Page 559 FUEL INJECTION SYSTEM Fault code No. Item Primary injector: open or short circuit detected. Connection of wire harness Improperly connected Con- Execute the diagnostic mode. ECU coupler. nect the coupler securely or (Code No. 36, 37, 38, 39) Check the locking condition of replace the wire harness.
Page 560 FUEL INJECTION SYSTEM Fault code No. Item Secondary injector: open or short circuit detected. Actuation Actuates secondary injector #2 five times at one-second intervals. Illuminates the engine trouble and system warning light. Procedure Check that secondary injector #2 is actuated five times by listening for the operating sound.
Page 561 FUEL INJECTION SYSTEM Fault code No. Item Secondary injector: open or short circuit detected. Wire harness continuity. Open or short circuit Replace Execute the diagnostic mode. the wire harness. (Code No. 40, 41, 42, 43) Between secondary injector No operating sound Go to coupler and ECU coupler.
Page 562 FUEL INJECTION SYSTEM Fault code No. IMU (Inertial Measurement Unit): no normal signals are received Item from the IMU (Inertial Measurement Unit). Connection of wire harness Improperly connected Con- Turn the main switch to “ON”. ECU coupler. nect the coupler securely or Fault code number is not dis- Check the locking condition of replace the wire harness.
Page 563 FUEL INJECTION SYSTEM Fault code No. A Rear wheel sensor: no normal signals are received from the rear wheel sensor. Item B Neutral switch: open or short circuit is detected. C Clutch switch: open or short circuit is detected. Item Probable cause of Maintenance job Confirmation of service com-...
Page 564 FUEL INJECTION SYSTEM Fault code No. Rear wheel sensor: no normal signals are received from the rear wheel sensor. Item B Neutral switch: open or short circuit is detected. C Clutch switch: open or short circuit is detected. Wire harness continuity. Open or short circuit Replace Execute the diagnostic mode.
Page 565 FUEL INJECTION SYSTEM Fault code No. A Rear wheel sensor: no normal signals are received from the rear wheel sensor. Item B Neutral switch: open or short circuit is detected. C Clutch switch: open or short circuit is detected. Locate the malfunction. Execute the diagnostic mode.
Page 566 FUEL INJECTION SYSTEM Fault code No. Rear wheel sensor: no normal signals are received from the rear wheel sensor. Item B Neutral switch: open or short circuit is detected. C Clutch switch: open or short circuit is detected. Defective relay unit. Check the relay unit.
Page 567 FUEL INJECTION SYSTEM Fault code No. A Rear wheel sensor: no normal signals are received from the rear wheel sensor. Item B Neutral switch: open or short circuit is detected. C Clutch switch: open or short circuit is detected. Fail-safe system Able to start engine Able to drive vehicle Diagnostic code No.
Page 568 FUEL INJECTION SYSTEM Fault code No. A Rear wheel sensor: no normal signals are received from the rear wheel sensor. Item B Neutral switch: open or short circuit is detected. C Clutch switch: open or short circuit is detected. Connection of clutch switch con- Improperly connected Con- Execute the diagnostic mode.
Page 569 FUEL INJECTION SYSTEM Fault code No. Rear wheel sensor: no normal signals are received from the rear wheel sensor. Item B Neutral switch: open or short circuit is detected. C Clutch switch: open or short circuit is detected. Malfunction in ECU. Replace the ECU.
Page 570 FUEL INJECTION SYSTEM Fault code No. Fuel system voltage: incorrect voltage supplied to the fuel injector Item and fuel pump. Connection of wire harness Improperly connected Con- Start the engine and let it idle for ECU coupler. nect the coupler securely or approximately 5 seconds.
Page 571 FUEL INJECTION SYSTEM Fault code No. EEPROM fault code number: an error is detected while reading or Item writing on EEPROM. Procedure — Item Probable cause of Maintenance job Confirmation of service com- malfunction and check pletion Locate the malfunction. Execute the diagnostic mode.
Page 572 FUEL INJECTION SYSTEM Fault code No. EEPROM fault code number: an error is detected while reading or Item writing on EEPROM. “04” is indicated in diagnostic Change the CO concentration of Turn the main switch to “ON”. mode (code No. 60). EEPROM cylinder #4, and rewrite in Fault code number is not dis- data error for adjustment of CO...
Page 573 FUEL INJECTION SYSTEM Fault code No. Malfunction in ECU internal circuit (power source self cut off does Item not work) Condition of backup fuse. Backup fuse blown Replace 5 seconds after turning the main Check the backup fuse. the fuse or replace the wire har- switch from “ON”...
Page 574 FUEL INJECTION SYSTEM Fault code No. 50 Fault code No. Faulty ECU memory. (When this malfunction is detected in the ECU, Item the fault code number might not appear on the meter display.) Fail-safe system Able/Unable to start engine Able/Unable to drive vehicle Diagnostic code No.
Page 575 FUEL INJECTION SYSTEM Fault code No. Item Accelerator position sensor: open or short circuit detected. Wire harness continuity. Open or short circuit Replace Turn the main switch to “ON”. the wire harness. Fault code number is not dis- Between accelerator position played Service is finished.
Page 576 FUEL INJECTION SYSTEM Fault code No. Item YCC-T drive system: malfunction detected. Meter display — Procedure — Item Probable cause of Maintenance job Confirmation of service com- malfunction and check pletion Connection of throttle servo Improperly connected Con- Turn the main switch to “ON”. motor coupler.
Page 577 FUEL INJECTION SYSTEM Fault code No. 66 Fault code No. Item Steering damper solenoid: open or short circuit detected. Fail-safe system Able to start engine Able to drive vehicle Diagnostic code No. Actuation When the start/engine stop switch is “ON”, the steering damper solenoid is on.
Page 578 FUEL INJECTION SYSTEM Fault code No. 68 Fault code No. Item sensor 2: no normal signals are received from the O sensor 2. Fail-safe system Able to start engine Able to drive vehicle Diagnostic code No. — Meter display — Procedure —...
Page 579 FUEL INJECTION SYSTEM Fault code No. Item sensor 2: no normal signals are received from the O sensor 2. Defective O sensor 2. Check the O sensor 2. Start the engine, warm it up, and then race it, or execute the Replace if defective.
Page 580 FUEL INJECTION SYSTEM Fault code No. Front wheel sensor: no normal signals are received from the front Item wheel sensor. Connection of ABS ECU cou- Improperly connected Con- Execute the diagnostic mode. pler. nect the coupler securely or (Code No. 16) Check the locking condition of replace the wire harness.
Page 581 FUEL INJECTION SYSTEM Fault code No. 89 (Yamaha diagnostic tool) 89 (Yamaha diagnostic tool) Fault code No. Err (multi-function meter display) Multi-function meter: signals cannot be transmitted between the Item ECU and the multi-function meter. Fail-safe system Able to start engine Able to drive vehicle Diagnostic code No.
Page 582 FUEL INJECTION SYSTEM Fault code No. 98 Fault code No. The ECU cannot receive fault signals from the IMU, or it cannot Item receive normal signals. Fail-safe system Able/Unable to start engine Able/Unable to drive vehicle Diagnostic code No. — Meter display —...
Page 583 FUEL INJECTION SYSTEM Fault code No. 99 Fault code No. Item No signal exchange between ECU and IMU. Fail-safe system Unable to start engine Able/Unable to drive vehicle Diagnostic code No. — Meter display — Procedure — Item Probable cause of Maintenance job Confirmation of service com- malfunction and check...
Page 584 FUEL PUMP SYSTEM EAS20081 FUEL PUMP SYSTEM EAS30513 CIRCUIT DIAGRAM For YZF-R1 8-103...
Page 585 FUEL PUMP SYSTEM 3. Main switch 4. Main fuse 7. Fuel injection system fuse 9. Backup fuse 12.Ignition fuse 18.Joint coupler 19.Battery 20.Engine ground 25.Handlebar switch (right) 28.Start/engine stop switch 29.Relay unit 31.Fuel pump relay 35.Fuel pump 37.ECU (Engine Control Unit) 60.Joint connector 8-104...
Page 586 FUEL PUMP SYSTEM For YZF-R1M 8-105...
Page 587 FUEL PUMP SYSTEM 3. Main switch 4. Main fuse 7. Fuel injection system fuse 9. Backup fuse 12.Ignition fuse 18.Joint coupler 19.Battery 20.Engine ground 25.Handlebar switch (right) 28.Start/engine stop switch 29.Relay unit 31.Fuel pump relay 35.Fuel pump 37.ECU (Engine Control Unit) 60.Joint connector 8-106...
Page 588 FUEL PUMP SYSTEM EAS30514 TROUBLESHOOTING If the fuel pump fails to operate. • Before troubleshooting, remove the following part(s): 1. Front side cowling/Front panel 2. Rider seat 3. Fuel tank cover 4. Fuel tank 1. Check the fuses. (Main, ignition, backup and fuel in- jection system) Replace the fuse(s).
Page 589 FUEL PUMP SYSTEM 8-108...
Page 590 IMMOBILIZER SYSTEM EAS20084 IMMOBILIZER SYSTEM EAS30519 CIRCUIT DIAGRAM For YZF-R1 8-109...
Page 591 IMMOBILIZER SYSTEM 3. Main switch 4. Main fuse 9. Backup fuse 12.Ignition fuse 18.Joint coupler 19.Battery 20.Engine ground 24.Immobilizer unit 37.ECU (Engine Control Unit) 60.Joint connector 76.Meter assembly 77.Immobilizer system indicator light 81.Multi-function meter 8-110...
Page 592 IMMOBILIZER SYSTEM For YZF-R1M 8-111...
Page 593 IMMOBILIZER SYSTEM 3. Main switch 4. Main fuse 9. Backup fuse 12.Ignition fuse 18.Joint coupler 19.Battery 20.Engine ground 24.Immobilizer unit 37.ECU (Engine Control Unit) 60.Joint connector 76.Meter assembly 77.Immobilizer system indicator light 81.Multi-function meter 8-112...
Page 594 IMMOBILIZER SYSTEM EAS30520 GENERAL INFORMATION This vehicle is equipped with an immobilizer system to help prevent theft by re-registering codes in the standard keys. This system consists of the following: • A code re-registering key (with a red bow) • Two standard keys (with a black bow) that can be re-registered with new codes •...
Page 595 IMMOBILIZER SYSTEM Parts to be replaced Main switch/ Key registration immobilizer unit Accessory requirement Standard lock* and Main Immobilizer switch unit Standard key is lost New standard key All keys have been lost Code re-registering (including code re-reg- key and standard keys istering key) Code re-registering ECU is defective...
Page 596 IMMOBILIZER SYSTEM Standard key registration: Standard key registration is required when a standard key is lost and needs to be replaced, or when the code re-registering key is re-registered after the immobilizer unit or ECU are replaced. Do not start the engine with a standard key that has not been registered. If the main switch is turned “ON”...
Page 597 IMMOBILIZER SYSTEM Standard key code voiding method a. Main switch “ON” b. Main switch “OFF” c. LED on d. LED off e. Less than 5.0 s f. Code re-registering key g. Remaining standard key h. Registration mode A. If the immobilizer system indicator light stops flashing 5 seconds after the first standard key is registered, the second standard key cannot be registered.
Page 598 IMMOBILIZER SYSTEM EAS30522 TROUBLESHOOTING When the main switch is turned to “ON”, the immobilizer system indicator light does not come on nor flashes. 1. Check the fuses. (Main, ignition, and backup) Replace the fuse(s). Refer to “CHECKING THE FUSES” on page 8-180. 2.
Page 599 IMMOBILIZER SYSTEM Fault Part Symptom Cause Action code IMMOBILIZER Codes cannot be Noise interference or dis- 1. Check the wire UNIT transmitted between connected lead/cable. harness and con- the ECU and the 1. Interference due to nector. immobilizer unit. radio wave noise. 2.
Page 600 ABS (Anti-lock Brake System) EAS20085 ABS (Anti-lock Brake System) EAS30843 CIRCUIT DIAGRAM For YZF-R1 8-119...
Page 601 58.Front wheel sensor 59.Rear wheel sensor 60.Joint connector 61.Yamaha diagnostic tool coupler 64.IMU (Inertial Measurement Unit) 76.Meter assembly 81.Multi-function meter 87.ABS warning light 90.Rear brake light switch 107.Tail/brake light A. Wire harness C. Sub-wire harness (Yamaha diagnostic tool coupler) 8-120...
Page 602 ABS (Anti-lock Brake System) For YZF-R1M 8-121...
Page 603 59.Rear wheel sensor 60.Joint connector 61.Yamaha diagnostic tool coupler 64.IMU (Inertial Measurement Unit) 76.Meter assembly 81.Multi-function meter 87.ABS warning light 90.Rear brake light switch 107.Tail/brake light A. Wire harness C. Sub-wire harness (Yamaha diagnostic tool coupler, CCU, GPS unit) 8-122...
Page 604 ABS (Anti-lock Brake System) EAS30525 ABS COMPONENTS CHART 11 12 3, 4 8-123...
Page 605 3. ABS ECU fuse 4. ABS solenoid fuse 5. Front wheel sensor rotor 6. Front wheel sensor 7. Front brake caliper 8. Rear wheel sensor 9. Rear wheel sensor rotor 10.Rear brake caliper 11.Yamaha diagnostic tool coupler 12.ABS motor fuse 8-124...
Page 606 ABS (Anti-lock Brake System) EAS30844 ABS COUPLER LOCATION CHART 8-125...
Page 607 ABS (Anti-lock Brake System) 1. Meter assembly coupler 2. Front wheel sensor coupler 3. ABS ECU coupler 4. Yamaha diagnostic tool coupler 5. Rear wheel sensor coupler 8-126...
Page 608 Previous malfunctions can be checked since the ABS ECU also stores the mal- function history. The fault codes recorded in the ABS ECU can be checked using the Yamaha diagnostic tool. When the service is finished, check the normal operation of the vehicle, and then delete the fault code(s). For in-...
Page 609 Since all malfunctions are recorded after they are detected, it is possible to check the recorded malfunction data by utilizing the Yamaha diagnostic tool when the ABS ECU has entered the self-diagnosis mode.
Page 610 ABS ECU? The hydraulic unit assembly • is defective. Can communicate [A-5] ABS ECU and FI ECU The connection with the Yamaha • Return to [A]. fail to communicate. diagnostic tool is defective. The battery voltage is low. •...
Page 611 EAS31162 [A-3] THE ABS WARNING LIGHT COMES ON Connect the Yamaha diagnostic tool to the Yamaha diagnostic tool coupler and execute functional di- agnosis. (For information about how to execute functional diagnosis, refer to the operation manual that is included with the tool.) Check that communication with the ABS ECU is possible.
Page 612 Check for continuity between black terminal of the ABS ECU coupler and the ground. If there is no continuity, the wire harness is defective. Replace the wire harness. • Open circuit in the wire harness between the ABS ECU coupler and the Yamaha diagnostic tool cou- pler.
Page 613 Once all the work is complete, delete the fault codes. [B-3] • When the Yamaha diagnostic tool is connected to the vehicle, the operation of the multi-function me- ter and indicators will be different from the normal operation.
Page 614 ABS (Anti-lock Brake System) The following icons and the fault code numbers for the detected malfunctions are displayed. B. Recovered malfunction A. Detected malfunction 4. ECU The types of the control units are displayed. (e.g., FI, ABS) 5. Item The item names of the detected malfunction are displayed. 6.
Page 615 ABS (Anti-lock Brake System) Fault code Item Symptom Check point Front wheel sensor (abnor- Front wheel sensor signal is • Foreign material adhered mal pulse period) not received properly. (The around the front wheel sen- pulse period is abnormal • Incorrect installation of the while the vehicle is traveling.) front wheel •...
Page 616 ABS (Anti-lock Brake System) Fault code Item Symptom Check point Hydraulic unit assembly Power is not supplied to the • Blown ABS motor fuse • Defective coupler between (abnormal ABS motor power motor circuit in the hydraulic supply) unit assembly. the battery and the hydrau- lic unit assembly •...
Page 617 ABS (Anti-lock Brake System) Fault code Item Symptom Check point Vehicle system power supply Power voltage supplied to • Defective battery • Defective coupler between (voltage of ABS ECU power the ABS ECU in the hydrau- supply is low) lic unit assembly is too low. the battery and the hydrau- lic unit assembly •...
Page 618 ABS (Anti-lock Brake System) Fault code Item Symptom Check point CAN communication Transmitted data from the FI • Defective coupler between (between FI ECU and ECU cannot be normally FI ECU and hydraulic unit hydraulic unit assembly) received. assembly • Harness is broken or short- circuit between FI ECU and hydraulic unit assembly •...
Page 619 ABS (Anti-lock Brake System) Fault code No. 12 Fault code No. Item Rear wheel sensor (intermittent pulses or no pulses) Rear wheel sensor signal is not received properly. (Pulses are not Symptom received or are received intermittently while the vehicle is travel- ing.) Order Item/components and probable cause Check or maintenance job...
Page 620 ABS (Anti-lock Brake System) • If the front brake ABS operates continuously for 20 seconds or more, fault code No. 26 will be record- ed. If the front brake ABS operates continuously for 36 seconds or more, fault code No. 13 will be re- corded.
Page 621 ABS (Anti-lock Brake System) Fault code No. Item Front wheel sensor (open or short circuit) Symptom Open or short circuit is detected in the front wheel sensor. Order Item/components and probable cause Check or maintenance job • Check for continuity between the white terminal “1” Open or short circuit in the wire harness between the front wheel sensor and the and the white terminal “4”...
Page 622 ABS (Anti-lock Brake System) Fault code No. Item Rear wheel sensor (open or short circuit) Symptom Open or short circuit is detected in the rear wheel sensor. Order Item/components and probable cause Check or maintenance job • Check for continuity between the white terminal “1” Open or short circuit in the wire harness between the rear wheel sensor and the and the white terminal “4”...
Page 623 ABS (Anti-lock Brake System) Fault code No. 31 Fault code No. Item Hydraulic unit assembly (defective ABS solenoid power circuit) Power is not supplied to the solenoid circuit in the hydraulic unit Symptom assembly. Order Item/components and probable cause Check or maintenance job Blown ABS solenoid fuse Check the ABS solenoid fuse.
Page 624 ABS (Anti-lock Brake System) Fault code No. 34 Fault code No. Hydraulic unit assembly (short circuit in ABS motor power supply Item circuit) Short circuit is detected in the motor power supply circuit in the Symptom hydraulic unit assembly. Order Item/components and probable cause Check or maintenance job Defective hydraulic unit assembly Replace the hydraulic unit assembly.
Page 625 ABS (Anti-lock Brake System) Fault code No. 42 Fault code No. Rear wheel ABS (intermittent wheel speed pulses or incorrect Item depressurization) • Pulses from the rear wheel sensor are received intermittently while the vehicle is traveling. Symptom • Rear wheel will not recover from the locking tendency even though the signal is transmitted from the ABS ECU to reduce the hydraulic pressure.
Page 626 ABS (Anti-lock Brake System) After the fault code No. 45 is recorded, fault code No. 43 will be recorded if a certain speed and time are exceeded. Fault code No. 44, 46 Fault code No. Item Rear wheel sensor (missing pulses) Rear wheel sensor signal is not received properly.
Page 627 ABS (Anti-lock Brake System) Fault code No. 53 Fault code No. Vehicle system power supply (voltage of ABS ECU power supply is Item low) Power voltage supplied to the ABS ECU in the hydraulic unit assem- Symptom bly is too low. Order Item/components and probable cause Check or maintenance job Defective battery...
Page 628 ABS (Anti-lock Brake System) Fault code No. 57 Fault code No. Item Vehicle CAN communication line or power source of vehicle system Short-circuit in CAN communication line or the voltage that sup- Symptom plies the hydraulic unit assembly is too low. Order Item/components and probable cause Check or maintenance job Short-circuit in CAN communication line...
Page 629 ABS (Anti-lock Brake System) Fault code No. 63 Fault code No. Item Defective front pressure sensor Abnormality detected in pressure sensor circuit at front master cyl- Symptom inder side of hydraulic unit assembly. Order Item/components and probable cause Check or maintenance job Defective front brake line Check the front brake line, and if there is bending or blocking, replace the front brake line.
Page 630 ABS (Anti-lock Brake System) Fault code No. Item Defective hydraulic unit assembly (defective rear pressure sensor) Abnormality detected in pressure sensor circuit of hydraulic unit Symptom assembly. Order Item/components and probable cause Check or maintenance job Defective hydraulic unit assembly Replace the hydraulic unit assembly.
Page 631 EAS31167 [B-3] DELETING THE FAULT CODES To delete the fault codes, use the Yamaha diagnostic tool. For information about deleting the fault codes, refer to the operation manual of the Yamaha diagnostic tool. Check that all the displayed fault codes are deleted.
Page 632 ABS (Anti-lock Brake System) EAS31168 [C-1] FINAL CHECK Check all the following items to complete the inspection. If the process is not completed properly, start again from the beginning. Checking procedures 1. Check the brake fluid level in the brake master cylinder reservoir and brake fluid reservoir. Refer to “CHECKING THE BRAKE FLUID LEVEL”...
Page 633 ABS (Anti-lock Brake System) 8-152...
Page 634 ELECTRONICALLY ADJUSTABLE SUSPENSION SYSTEM (for YZF-R1M) EAS20168 ELECTRONICALLY ADJUSTABLE SUSPENSION SYSTEM (for YZF-R1M) EAS31009 CIRCUIT DIAGRAM 8-153...
Page 635 (compression damping) 118.Rear shock absorber assembly stepping motor (rebound damping) 119.Steering damper solenoid (OPTION) A. Wire harness C. Sub-wire harness (Yamaha diagnostic tool coupler, CCU, GPS unit) D. Sub-wire harness (SCU, steering damper solenoid, sub-wire harness) E. Sub-wire harness (damper solenoid) F.
Page 636 ELECTRONICALLY ADJUSTABLE SUSPENSION SYSTEM (for YZF-R1M) EAS31010 MAINTENANCE OF THE SCU (Suspension Control Unit) Checking the SCU (Suspension Control Unit) 1. Check: • Terminals “1” of the SCU Cracks/damages Replace the SCU. • Terminals “2” of the SCU couplers Connection defective, contaminated, come-off Replace or clean.
Page 637 If another fault code number is displayed, repeat steps (1) to (4) until no fault code number is displayed. EAS31013 BASIC INSTRUCTIONS FOR DIAGNOSTIC FUNCTION Use the Yamaha diagnostic tool and determine the location of the malfunction and the cause from the recorded fault code. Refer to “YAMAHA DIAGNOSTIC TOOL” on page 8-52. EAS31014 TROUBLESHOOTING DETAILS (SCU) This section describes the measures per fault code number displayed on the display.
Page 638 ELECTRONICALLY ADJUSTABLE SUSPENSION SYSTEM (for YZF-R1M) Fault code No. Item Abnormal ABS Indicated — Procedure — Item Probable cause of Maintenance job Confirmation of service com- malfunction and check pletion Abnormal ABS Check the items of fault codes Turn the main switch to “OFF” No.
Page 639 ELECTRONICALLY ADJUSTABLE SUSPENSION SYSTEM (for YZF-R1M) Fault code No. 10 Fault code No. Item Abnormal CAN communication (between ABS ECU and SCU) Fail-safe system Able to start engine Able to drive vehicle Diagnostic code No. — Indicated — Procedure — Item Probable cause of Maintenance job...
Page 640 ELECTRONICALLY ADJUSTABLE SUSPENSION SYSTEM (for YZF-R1M) Fault code No. 44 Fault code No. Item Abnormal SCU EEPROM Fail-safe system Able to start engine Able to drive vehicle Diagnostic code No. — Indicated — Procedure — Item Probable cause of Maintenance job Confirmation of service com- malfunction and check pletion...
Page 641 ELECTRONICALLY ADJUSTABLE SUSPENSION SYSTEM (for YZF-R1M) Fault code No. Item Abnormality inside SCU Diagnostic code No. — Indicated — Procedure — Item Probable cause of Maintenance job Confirmation of service com- malfunction and check pletion Malfunction in SCU. Replace the SCU. Turn the main switch to “OFF”...
Page 642 ELECTRONICALLY ADJUSTABLE SUSPENSION SYSTEM (for YZF-R1M) Fault code No. Steering damper stepping motor (manufactured by Öhlins: Item optional): open circuit or short-circuit detected. Wire harness continuity. Open circuit Replace the Turn the main switch to “OFF” wire harness. and back to “ON”. •...
Page 643 ELECTRONICALLY ADJUSTABLE SUSPENSION SYSTEM (for YZF-R1M) Fault code No. Steering damper stepping motor (manufactured by Öhlins: Item optional): open circuit or short-circuit detected. Malfunction in stepping motor. Stepping motor confirmation Turn the main switch to “ON”. steps: Fault code number is not dis- a.
Page 644 ELECTRONICALLY ADJUSTABLE SUSPENSION SYSTEM (for YZF-R1M) Fault code No. 89 (or “Err” is displayed) Item Abnormal CAN communication (between meter assembly and SCU) Diagnostic code No. — Indicated — Procedure — Item Probable cause of Maintenance job Confirmation of service com- malfunction and check pletion Connection of meter assembly...
Page 645 ELECTRONICALLY ADJUSTABLE SUSPENSION SYSTEM (for YZF-R1M) Fault code No. Item Stepping motor: open or short circuit detected. Connection of SCU coupler. Improperly connected Con- Turn the main switch to “OFF” Check the locking condition of nect the coupler securely or and back to “ON”.
Page 646 ELECTRONICALLY ADJUSTABLE SUSPENSION SYSTEM (for YZF-R1M) Fault code No. Item Stepping motor: open or short circuit detected. Wire harness continuity. • Between rear shock absorber Turn the main switch to “OFF” assembly stepping motor and back to “ON”. (compression damping) “4” Fault code number is not dis- and power ground “2”.
Page 647 ELECTRONICALLY ADJUSTABLE SUSPENSION SYSTEM (for YZF-R1M) Fault code No. Item Stepping motor: open or short circuit detected. Malfunction in stepping motor. Stepping motor confirmation Turn the main switch to “ON”. steps: Fault code number is not dis- a. Connect the pocket tester ( played Service is finished.
Page 648 ELECTRONICALLY ADJUSTABLE SUSPENSION SYSTEM (for YZF-R1M) Fault code No. 98 Fault code No. Item Abnormal IMU Fail-safe system Able/Unable to start engine Able/Unable to drive vehicle Diagnostic code No. — Indicated — Procedure — Item Probable cause of Maintenance job Confirmation of service com- malfunction and check pletion...
Page 649 ELECTRONICALLY ADJUSTABLE SUSPENSION SYSTEM (for YZF-R1M) Fault code No. — Fault code No. ERS icon blinks Zero point adjustment of damping force adjustment system was not Item performed. Fail-safe system Unable to start engine Able/Unable to drive vehicle Diagnostic code No. —...
Page 650 COMMUNICATION CONTROL SYSTEM (for YZF-R1M) EAS20212 COMMUNICATION CONTROL SYSTEM (for YZF-R1M) EAS31671 CIRCUIT DIAGRAM 8-169...
Page 651 20.Engine ground 37.ECU (Engine Control Unit) 60.Joint connector 61.Yamaha diagnostic tool coupler 62.CCU (Communication Control Unit) 63.GPS unit 64.IMU (Inertial Measurement Unit) 76.Meter assembly 81.Multi-function meter A. Wire harness C. Sub-wire harness (Yamaha diagnostic tool coupler, CCU, GPS unit) 8-170...
Page 652 COMMUNICATION CONTROL SYSTEM (for YZF-R1M) EAS31672 TROUBLESHOOTING The communication control system failed to function. • Before troubleshooting, remove the following part(s): 1. Front side cowling/Front panel/Side cover 2. Rider seat/Passenger seat/Battery cover/Tail cover 1. Check the fuses. (Main, ignition and backup) Replace the fuse(s).
Page 653 COMMUNICATION CONTROL SYSTEM (for YZF-R1M) 8-172...
Page 654: Electrical Components
ELECTRICAL COMPONENTS EAS20089 ELECTRICAL COMPONENTS 8-173...
Page 655 ELECTRICAL COMPONENTS 1. Intake funnel servo motor 2. Accelerator position sensor 3. Throttle servo motor 4. Intake air pressure sensor 5. Primary injector 6. Throttle position sensor 7. Secondary injector 8. Fuel pump 9. Battery 10.GPS unit (for YZF-R1M) 11.CCU (Communication Control Unit) (for YZF- R1M) 12.EXUP servo motor 13.IMU (Inertial Measurement Unit)
Page 656 ELECTRICAL COMPONENTS 8-175...
Page 657 ELECTRICAL COMPONENTS 1. Fuse box 1 2. Atmospheric pressure sensor 3. Front fork stepping motor (for YZF-R1M) 4. Air induction system solenoid 5. Ignition coil 6. Coolant temperature sensor 7. Neutral switch 8. Rear shock absorber assembly stepping motor (for YZF-R1M) 9.
Page 658 ELECTRICAL COMPONENTS EAS30549 CHECKING THE SWITCHES 8-177...
Page 659 ELECTRICAL COMPONENTS 1. Start/engine stop switch 2. Mode switch 3. Pass/LAP switch 4. Dimmer switch 5. Horn switch 6. Turn signal switch 7. Hazard switch 8. Clutch switch 9. Sidestand switch 10.Main switch 11.Front brake light switch 12.Shift switch 13.Neutral switch 14.Rear brake light switch 8-178...
Page 660 ELECTRICAL COMPONENTS Check each switch for continuity with the pocket tester. If the continuity reading is incorrect, check the wiring connections and if necessary, replace the switch. ECA14371 NOTICE Never insert the tester probes into the coupler terminal slots. Always insert the probes from the opposite end “a”...
Page 661 ELECTRICAL COMPONENTS EAS30551 Amperage CHECKING THE FUSES Fuses Q’ty rating The following procedure applies to all of the fus- ABS motor 30.0 A ECA13680 ABS ECU 7.5 A NOTICE To avoid a short circuit, always set the main ABS solenoid 15.0 A switch to “OFF”...
Page 662 • No charging is necessary when the open-cir- NOTICE cuit voltage equals or exceeds 12.8 V. Use only the specified genuine YAMAHA bat- tery. Using a different battery may cause the b. Check the charge of the battery, as shown in...
Page 663 ELECTRICAL COMPONENTS it from the vehicle. (If charging has to be the charts and the following example. done with the battery mounted on the vehi- Example cle, disconnect the negative battery lead Open-circuit voltage = 12.0 V from the battery terminal.) Charging time = 6.5 hours Charge of the battery = 20–30 % •...
Page 664 ELECTRICAL COMPONENTS b. Connect a charger and ammeter to the bat- charger cannot charge the VRLA (Valve Regu- tery and start charging. lated Lead Acid) battery. A variable voltage charger is recommended. Set the charging voltage to 16–17 V. If the set- d.
Page 665 ELECTRICAL COMPONENTS Relay unit (starting circuit cut-off relay) 8. Check: • Battery terminals Dirt Clean with a wire brush. Loose connection Connect properly. 9. Lubricate: • Battery terminals Recommended lubricant Br/W L/W Dielectric grease L/R L/W R/W L/B L/Y Sb B/Y Sb/W 10.Install: •...
Page 666 ELECTRICAL COMPONENTS Radiator fan motor relay Continuity Positive tester probe sky blue “1” Negative tester probe black/yellow “2” No continuity Positive tester probe black/yellow “2” Negative tester probe sky blue “1” Continuity Positive tester probe 1. Positive battery terminal sky blue “1” 2.
Page 667 ELECTRICAL COMPONENTS unit terminal as shown. Pocket tester c. Check the relay unit (diode) for continuity. 90890-03112 d. Check the relay unit (diode) for no continuity. Analog pocket tester ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ YU-03112-C EAS30558 CHECKING THE IGNITION COILS • Negative tester probe Ignition coil terminal “1”...
Page 668 ELECTRICAL COMPONENTS b. Measure the crankshaft position sensor re- 2. Ignition coil sistance. c. Turn the main switch to “ON”. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ d. Measure the ignition spark gap “a”. e. Crank the engine by pushing the “ ” side of EAS30562 the start/engine stop switch and gradually in- CHECKING THE STARTER MOTOR crease the spark gap until a misfire occurs.
Page 669 ELECTRICAL COMPONENTS (from the wire harness) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ 2. Check: a. Connect the pocket tester (AC 20 V) to the • Stator coil resistance rectifier/regulator coupler as shown. Out of specification Replace the stator coil. Pocket tester Stator coil resistance 90890-03112 0.112–0.168 (W-W) Analog pocket tester...
Page 670 ELECTRICAL COMPONENTS • Positive tester probe positive battery terminal “1” • Negative tester probe negative battery terminal “2” c. Measure the horn resistance. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 2. Check: • Horn sound Faulty sound Replace. b. Start the engine and let it run at approximate- ly 5000 r/min.
Page 671 ELECTRICAL COMPONENTS EAS30574 EAS30578 CHECKING THE FUEL LEVEL WARNING CHECKING THE COOLANT TEMPERATURE LIGHT SENSOR This model is equipped with a self-diagnosis de- 1. Remove: • Coolant temperature sensor vice for the fuel level detection circuit. 1. Check: Refer to “CYLINDER HEAD” on page 5-23. •...
Page 672 ELECTRICAL COMPONENTS ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the pocket tester ( 1 k) to the throttle position sensor terminals as shown. Pocket tester 90890-03112 Analog pocket tester YU-03112-C • Positive tester probe blue “1” • Negative tester probe black/green “2” d. Heat the coolant or let it cool down to the specified temperatures.
Page 673 ELECTRICAL COMPONENTS tle servo motor. Resistance 1.40–2.60 k Do not use old batteries to operate the throttle servo motor. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the pocket tester ( 1 k) to the ac- celerator position sensor terminals as shown. Pocket tester 90890-03112 Analog pocket tester YU-03112-C •...
Page 674 ELECTRICAL COMPONENTS • Positive tester probe • Positive tester probe orange “1” pink (wire harness color) • Negative tester probe • Negative tester probe green “2” black/blue (wire harness color) c. Measure the air induction system solenoid re- c. Set the main switch to “ON”. sistance.
Page 675 ELECTRICAL COMPONENTS test harness S– pressure sensor (3P). Pocket tester 90890-03112 Digital circuit tester Analog pocket tester 90890-03174 YU-03112-C Model 88 Multimeter with tachom- Test harness– speed sensor (3P) eter 90890-03208 YU-A1927 Test harness– speed sensor (3P) Test harness S– pressure sensor YU-03208 (3P) 90890-03207...
Page 676: Specifications
ELECTRICAL COMPONENTS ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ • Positive tester probe a. Connect the pocket tester ( 100) to the in- Solenoid terminal “1” • Negative tester probe take air temperature sensor terminal as Solenoid terminal “2” shown. Pocket tester 90890-03112 Analog pocket tester YU-03112-C b.
Page 677 ELECTRICAL COMPONENTS c. Measure the fuel injector resistance. c. Measure the steering damper solenoid resis- ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ tance. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS31673 CHECKING THE WHEEL SWITCH EAS30681 1. Check: CHECKING THE FUEL INJECTORS • Wheel switch “1” output voltage The following procedure applies to all of the fuel Out of specification Replace the right han- injectors.
Page 678 ELECTRICAL COMPONENTS “a”, check that the output voltage is within the specified values. Output voltage More than 5 V f. When turning the wheel switch in direction “b”, check that the output voltage is within the specified values. Output voltage Less than 0.5 V ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲...
Page 679: Engine
TROUBLESHOOTING TROUBLESHOOTING..................9-1 GENERAL INFORMATION ................9-1 STARTING FAILURES................9-1 INCORRECT ENGINE IDLING SPEED .............9-1 POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE ......9-2 FAULTY GEAR SHIFTING.................9-2 SHIFT PEDAL DOES NOT MOVE .............9-2 JUMPS OUT OF GEAR................9-2 FAULTY CLUTCH ..................9-2 OVERHEATING ..................9-2 OVERCOOLING..................9-3 POOR BRAKING PERFORMANCE............9-3 FAULTY FRONT FORK LEGS..............9-3 UNSTABLE HANDLING ................9-3 FAULTY LIGHTING OR SIGNALING SYSTEM .........9-3 TROUBLESHOOTING AT THE ABS WARNING LIGHT ......9-4...
Page 680 TROUBLESHOOTING 2. Fuse(s) EAS20090 TROUBLESHOOTING • Blown, damaged or incorrect fuse • Improperly installed fuse EAS30599 3. Spark plug(s) GENERAL INFORMATION • Incorrect spark plug gap • Incorrect spark plug heat range The following guide for troubleshooting does not • Fouled spark plug cover all the possible causes of trouble.
Page 681: Cooling System
TROUBLESHOOTING • Worn or damaged electrode EAS30849 FAULTY CLUTCH • Worn or damaged insulator Clutch slips 3. Ignition coil(s) 1. Clutch • Broken or shorted primary or secondary coils • Improperly assembled clutch • Cracked or broken ignition coil • Improperly adjusted clutch cable 4.
Page 682: Chassis
TROUBLESHOOTING • Damaged pipe • Faulty front fork stepping motor (for YZF-R1M) • Improperly connected pipe EAS30611 Fuel system UNSTABLE HANDLING 1. Throttle body (-ies) Handlebar • Damaged or loose throttle body joint • Bent or improperly installed handlebar 2. Air filter Steering head components •...
Page 683: Troubleshooting
TROUBLESHOOTING • Incorrect connection • Faulty tail/brake light assembly Turn signal does not come on • Faulty turn signal switch • Faulty meter assembly • Faulty turn signal light • Incorrect connection • Damaged or faulty wire harness • Improperly grounded circuit •...
Page 684 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE (ECU) EAS20162 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE (ECU) If there is a malfunction in the fuel injection system, the engine trouble and system warning light “1” will come on, and a fault code number “2” will be displayed. If there are malfunctions in other systems, refer to the troubleshooting sections for the systems indicated by the warning indicators.
Page 685 COMMUNICATION ERROR WITH THE METER For details of the fault code, refer to “TROUBLESHOOTING METHOD (ECU)” on page 8-50. Fault code No. Item 89 (Yamaha diagnostic tool) Multi-function meter: signals cannot be transmitted between the ECU and Err (multi-function meter dis- the multi-function meter.
Page 686 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE (ECU) EAS31057 DIAGNOSTIC CODE: SENSOR OPERATION TABLE Diagnostic Item Meter display Procedure code No. Throttle position sensor sig- nal 1 • Fully closed position 11–21 Check with throttle valves fully closed. • Fully open position 96–106 Check with throttle valves fully open.
Page 687 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE (ECU) Diagnostic Item Meter display Procedure code No. Accelerator position sensor signal 2 • Fully closed position 10–24 Check with throttle grip fully closed position. • Fully open position 95–109 Check with throttle grip fully open position.
Page 688 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE (ECU) Diagnostic Item Meter display Procedure code No. Malfunction history code dis- — play • No history • History exists Fault codes 8–99 • (If more than one code number is detected, the display alternates every two seconds to show all the detected code numbers.
Page 689 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE (ECU) EAS31058 DIAGNOSTIC CODE: ACTUATOR OPERATION TABLE Diagnostic Item Actuation Procedure code No. Cylinder-#1 ignition coil Actuates the cylinder-#1 igni- Check that a spark is gener- tion coil five times at one- ated five times. •...
Page 690 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE (ECU) Diagnostic Item Actuation Procedure code No. Secondary injector #3 Actuates the secondary Check that secondary injec- injector #3 five times at one- tor #3 is actuated five times second intervals. by listening for the operating Illuminates the engine trou- sound.
Page 691 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE (SCU) (for YZF-R1M) EAS20163 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE (SCU) (for YZF-R1M) If there is a malfunction in the electronically adjustable suspension system, the engine trouble and sys- tem warning light “1” will come on, and a fault code number “2” will be displayed. 12 : 00 1000 r/min ×...
Page 692 EVENT CODE TABLE EAS20164 EVENT CODE TABLE The event code numbers listed below cannot be displayed on the meter. To display the event code numbers, use the Yamaha diagnostic tool. Item Symptom Possible causes Note Intake air pres- Brief abnormality...
Page 693 EVENT CODE TABLE Item Symptom Possible causes Note During idling, the Idling engine speed is – Implement diagnosis (Stuck at the adjustment is main- slow mode D67, and check upper limit for tained at the upper – Clogged throttle body the ISC maintenance adjustment) limit...
Page 694 EVENT CODE TABLE 9-15...
Page 695: Wiring Diagram
58. Front wheel sensor 112.Auxiliary DC outlet 59. Rear wheel sensor YZF-R1/YZF-R1F 2015 60. Joint connector A. Wire harness 1. AC magneto 61. Yamaha diagnostic tool cou- B. Sub-wire harness (intake sole- 2. Rectifier/regulator pler noid) 3. Main switch 62. CCU (Communication Control C.
Page 696 YZF-R1M/YZF-R1MF 2015 59. Rear wheel sensor 113.SCU fuse 1. AC magneto 60. Joint connector 114.SCU (Suspension Control 2. Rectifier/regulator 61. Yamaha diagnostic tool cou- Unit) 3. Main switch pler 115.Front fork stepping motor (left) 4. Main fuse 62. CCU (Communication Control 116.Front fork stepping motor...
Page 697 Yellow/Green EAS30613 COLOR CODE Yellow/Blue Black Yellow/Red Brown Chocolate Dark green Green Gray Blue Light green Orange Pink Sky blue Violet White Yellow Black/Green Black/Blue Black/Red Black/White Black/Yellow Br/B Brown/Black Br/L Brown/Blue Br/R Brown/Red Br/W Brown/White Br/Y Brown/Yellow Green/Black Green/Blue Green/Orange Green/Red Green/White...
Page 701 YZF-R1/YZF-R1F 2015 YZF-R1/YZF-R1F 2015 YZF-R1/YZF-R1F 2015 YZF-R1/YZF-R1F 2015 YZF-R1/YZF-R1F 2015 WIRING DIAGRAM SCHÉMA DE CÂBLAGE SCHALTPLAN SCHEMA ELETTRICO DIAGRAMA ELÉCTRICO B/W R/G L/B L/W B/W R/G L/B L/W Y/L Lg R/W B W R W W W R/W R/W W W W Br/L Gy/R Gy/R...
Page 702 YZF-R1/YZF-R1F 2015 YZF-R1/YZF-R1F 2015 YZF-R1/YZF-R1F 2015 YZF-R1/YZF-R1F 2015 YZF-R1/YZF-R1F 2015 WIRING DIAGRAM SCHÉMA DE CÂBLAGE SCHALTPLAN SCHEMA ELETTRICO DIAGRAMA ELÉCTRICO (Gy) START (Gy) 7.5A (Gy) (Gy) 7.5A (Gy) 7.5A (Gy) (Gy) (Gy) 7.5A 7.5A 7.5A FREE DOWN (Gy) (Gy) (Gy)
Page 703 YZF-R1M/YZF-R1MF 2015 YZF-R1M/YZF-R1MF 2015 YZF-R1M/YZF-R1MF 2015 YZF-R1M/YZF-R1MF 2015 YZF-R1M/YZF-R1MF 2015 WIRING DIAGRAM SCHÉMA DE CÂBLAGE SCHALTPLAN SCHEMA ELETTRICO DIAGRAMA ELÉCTRICO B/W R/G L/B L/W Br/W Gy/R Gy/B Gy/G B/W R/G Br/W Gy/G Gy/B Gy Gy/R L/B L/W Y/L Lg R/W B W R W W W R/W R/W...
Page 704 YZF-R1M/YZF-R1MF 2015 YZF-R1M/YZF-R1MF 2015 YZF-R1M/YZF-R1MF 2015 YZF-R1M/YZF-R1MF 2015 YZF-R1M/YZF-R1MF 2015 WIRING DIAGRAM SCHÉMA DE CÂBLAGE SCHALTPLAN SCHEMA ELETTRICO DIAGRAMA ELÉCTRICO (Gy) START (Gy) 7.5A (Gy) (Gy) 7.5A (Gy) 7.5A (Gy) (Gy) (Gy) 7.5A 7.5A 7.5A FREE DOWN (Gy) (Gy) (Gy)

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