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Feb 15,  · Note: If you are trying to download and it does not work try downloading from an actual windows computer. R1 Service Manual. R1 Service Manual. R1 Service Manual. R1 Service Manual. R1 Service Manual. R1 Service Manual. R1 Service Manual. Summary of Contents for Yamaha YZF-R1 Page 3 FOREWORD This Supplementary Service Manual has been prepared to introduce new service and data for the YZF-R1 For complete service information procedures it is necessary to use this Supplementary Service Manual together with the following manual. FOREWORD. This Supplementary Service Manual has been prepared to introduce new service and data for the YZF-R1 For complete service information procedures it is necessary to use this Supplementary Service Manual together with the following manual.
 
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Yamaha YZF-R1 Manuals | ManualsLib

Check that the valves properly seal. NOTE: There should be no leakage at the valve seat 1. Valve spring compressor Attachment for the intake valve for the exhaust valve Valve-stem-to-valve-guide clearance Intake 0.

Remove the valve guide with a valve guide remover 1. Install the new valve guide with the valve guide installer 2 and valve guide remover 1. After installing the valve guide, bore the valve guide with a valve guide reamer 3 to obtain the proper valvestem-to-valve-guide clearance.

NOTE: After replacing the valve guide, reface the valve seat. Valve guide remover Intake 4. Valve margin thickness 0. Valve stem runout 0. Valve seat width 0. Install the valve into the cylinder head. Press the valve through the valve guide and onto the valve seat to make a clear impression.

Measure the valve seat width. NOTE: Where the valve seat and valve face contacted one another, the blueing will have been removed. Apply molybdenum disulfide oil onto the valve stem. Turn the valve until the valve face and valve seat are evenly polished, then clean off all of the lapping compound. NOTE: For the best lapping results, lightly tap the valve seat while rotating the valve back and forth between your hands.

Apply a fine lapping compound to the valve face and repeat the above steps. After every lapping procedure, be sure to clean off all of the lapping compound from the valve face and valve seat. Measure the valve seat width c again. If the valve seat width is out of specification, reface and lap the valve seat.

Valve spring free length Intake valve spring Compressed spring force installed Intake valve spring 8. Refer to the following embossed marks. Valve spring compressor Attachment for the intake valve spring for the exhaust valve spring 5.

To secure the valve cotters 1 onto the valve stem, lightly tap the valve tip with a soft-face hammer. Generator rotor cover Generator rotor cover gasket Dowel pin Generator rotor bolt Generator rotor Stator coil assembly coupler Stator coil assembly lead holder Stator coil assembly. After all of the bolts are fully loosened, remove them. Rotor holding tool 3. NOTE: While holding the generator rotor 2 with the rotor holding tool 3, tighten the generator rotor bolt.

Rotor holding tool 4. Generator rotor cover Clutch cable Clutch cable holder Pickup coil lead holder Pickup coil rotor cover Pickup coil rotor cover gasket Dowel pin. Rotor holding tool NOTE: While holding the generator rotor 2 with the rotor holding tool 3, tighten the pickup coil rotor bolt. Straighten the lock washer tab. Clutch holding tool 4. It is not necessary to remove the wire circlip 4 and disassemble the built-in damper unless there is serious clutch chattering.

NOTE: Measure the friction plate at four places. Friction plate thickness 2. NOTE: Pitting on the clutch housing dogs will cause erratic clutch operation. NOTE: Pitting on the clutch boss splines will cause erratic clutch operation.

Install the starter clutch gear 1 onto the starter clutch 2 and hold the starter clutch. NOTE: While holding the clutch boss 2 with the clutch holding tool 3, tighten the clutch boss nut. Bend the lock washer tab along a flat side of the nut. NOTE: Tighten the clutch spring plate retainer bolts in stages and in a crisscross pattern.

Make sure that the pull rod teeth and pull lever shaft pinion gear are engaged. Radiator assembly and water pump outlet pipe Exhaust pipe assembly Oil level switch connector Oil level switch Oil level switch lead holder Oil pan Oil pan gasket Dowel pin 4 – Inner-rotor-to-outer-rotor-tip clearance 0.

Place the engine upside down. Tap only on reinforced portions of the crankcase, not on the crankcase mating surfaces. Work slowly and carefully and make sure that the crankcase halves separate evenly. Thoroughly wash the crankcase halves in a mild solvent. Thoroughly clean all the gasket surfaces and crankcase mating surfaces. Set the shift drum assembly and transmission gears in the neutral position. If both areas are deburred and the piston pin is still difficult to remove, remove it with the piston pin puller 4.

Piston pin puller 3. Then, find the average of the measurements. If out of specification, replace the crankcases, and the pistons and piston rings as a set. Micrometer a 5 mm from the bottom edge of the piston. Calculate the piston-to-cylinder clearance with the following formula. NOTE: Before measuring the piston ring side clearance, eliminate any carbon deposits from the piston ring grooves and piston rings.

Piston ring side clearance Top ring 0. Piston ring end gap Top ring 0. Piston pin outside diameter Piston pin bore diameter in the piston Crankshaft-pin-to-big-endbearing clearance 0. To obtain the correct crankshaft-pin-to-big-end-bearing clearance and prevent engine damage, the big end bearings must be installed in their original positions.

Clean the big end bearings, crankshaft pins, and bearing portions of the connecting rods. Install the big end upper bearing into the connecting rod and the big end lower bearing into the connecting rod cap. NOTE: Align the projections a on the big end bearings with the notches b in the connecting rod and connecting rod cap. Assemble the connecting rod halves. Tighten the connecting rod nuts. Apply continuous torque between 2.

Once you reach 2. If the tightening is interrupted between 2. Remove the connecting rod and big end bearings. If the crankshaft-pin-to-big-end-bearing clearance is out of specification, select replacement big end bearings. Refer to the illustration. Crankshaft-journal-to-crankshaft-journal-bearing clearance 0. To obtain the correct crankshaft-journal-to-crankshaft-journal-bearing clearance and prevent engine damage, the crankshaft journal bearings must be installed in their original positions.

Clean the crankshaft journal bearings, crankshaft journals, and bearing portions of the crankcase. Place the upper crankcase upside down on a bench. Install the crankshaft journal upper bearings 1 and the crankshaft into the upper crankcase. NOTE: Align the projections a on the crankshaft journal upper bearings with the notches b in the upper crankcase.

Install the crankshaft journal lower bearings into the lower crankcase and assemble the crankcase. Tighten the bolts to specification in the tightening sequence cast on the crankcase. Remove the lower crankcase and the crankshaft journal lower bearings. If the clearance is out of specification, select replacement crankshaft journal bearings. Insert two bolts 2 of the proper size, as shown in the illustration, into the main axle assembly bearing housing.

Tighten the bolts until they contact the crankcase surface. Continue tightening the bolts until the main axle assembly comes free from the upper crankcase. NOTE: Oil each gear, shaft, and bearing thoroughly. Coolant reservoir breather hose Coolant reservoir hose Coolant reservoir Thermo switch coupler Temperature sender connector Ground lead.

Apply compressed air to the rear of the radiator. NOTE: Straighten any flattened fins with a thin, flat-head screwdriver. Install the radiator cap tester 1 and adapter 2 onto the radiator cap 3. Radiator cap tester Adapter b. Apply the specified pressure for ten seconds and make sure that there is no drop in pressure.

Oil cooler outlet hose Bolt Lock washer Oil cooler Oil cooler inlet hose Water pump outlet pipe Water jacket joint inlet hose Water jacket joint. Bend the lock washer tab along a flat side of the bolt. Radiator inlet hose Thermostat assembly breather hose Thermostat assembly inlet hose left Thermostat assembly inlet hose right. Suspend the thermostat in a container filled with water. Slowly heat the water. Place a thermometer in the water. NOTE: If the accuracy of the thermostat is in doubt, replace it.

A faulty thermostat could cause serious overheating or overcooling. Mechanical seal installer 4 Middle driven shaft bearing driver 5 Yamaha bond No. Starter cable Fuel hose Throttle position sensor coupler Float chamber air vent hose Throttle stop screw Carburetor joint clamp screw Throttle cable Carburetor assembly Carburetor joint.

NOTE: The following procedure applies to all of the carburetors. Wash the carburetor in a petroleumbased solvent.

Do not use any caustic carburetor cleaning solution. Blow out all of the passages and jets with compressed air. Blow out the jets with compressed air. Blow out the pipes with compressed air. Blow out the hoses with compressed air. Then, tighten the connecting bolts while pushing down the carburetor assembly with an even force.

Fuel level below the line on the float chamber 4. Place the motorcycle on a suitable stand to ensure that the motorcycle is standing straight up. Install the fuel level gauge 1 onto the fuel drain pipe 2. Fuel level gauge d. Loosen the fuel drain bolt 3. Hold the fuel level gauge vertically next to the line 4 on the float chamber. Measure the fuel level a. NOTE: Fuel level readings should be equal on both sides of the carburetor assembly.

Remove the carburetor assembly. Check the needle valve seat and needle valve. If either is worn, replace them as a set. If both are fine, adjust the float level by slightly bending the float tang 1. Install the carburetor assembly. Measure the fuel level again. Repeat steps a to f until the fuel level is within specification. Disconnect the throttle position sensor coupler. Measure the throttle position sensor maximum resistance. Throttle position sensor maximum resistance 4. While slowly opening the throttle, check that the throttle position sensor resistance is within the specified range.

NOTE: Check mainly that the resistance changes gradually when turning the throttle, since the readings from closed to wide-open throttle may differ slightly from those specified. Remove the throttle position sensor from the carburetor.

Reconnect the throttle position sensor coupler. NOTE: After reconnecting the throttle position sensor coupler, the tachometer switches to the throttle position sensor adjustment mode.

Loosen the throttle position sensor screws 1. Adjust the throttle position sensor angle according to the following table. Tachometer reading. After adjusting the throttle position sensor angle, tighten the throttle position sensor screws. Remove the fuel tank. Disconnect the fuel-pump-to-carburetor fuel hose 2 from the carburetor. Place a container under the end of the fuel hose 2. Start the engine and check if fuel flows from the fuel hose 2. Fuel flows.

Brake hose holder left and right Brake caliper left and right Wheel axle pinch bolt Front wheel axle Front wheel Collar left and right Oil seal cover left and right Brake disc left and right.

Clean the outside of the front wheel hub. Remove the oil seals 1 with a flathead screwdriver. NOTE: To prevent damaging the wheel, place a rag 2 between the screwdriver and the wheel surface.

Remove the wheel bearings with a general bearing puller. Remove the wheel bearings 3 with a general bearing puller. Install the new wheel bearings and oil seals in the reverse order of disassembly. Contact should be made only with the outer race 6. NOTE: Use a socket 7 that matches the diameter of the wheel bearing outer race and oil seal. Place the motorcycle on a suitable stand so that the wheel is elevated. Before measuring the front brake disc deflection, turn the handlebars to the left or right to ensure that the front wheel is stationary.

Remove the brake caliper. Hold the dial gauge at a right angle against the brake disc surface. Remove the brake disc. Rotate the brake disc by one bolt hole. Install the brake disc. NOTE: Tighten the brake disc bolts in stages and in a crisscross pattern. Measure the brake disc deflection. If out of specification, repeat the adjustment steps until the brake disc deflection is within specification. If the brake disc deflection cannot be brought within specification, replace the brake disc.

Contact should be made only with the outer race 3. NOTE: Use a socket 4 that matches the diameter of the wheel bearing outer race and oil seal. Place the front wheel on a suitable balancing stand. Spin the front wheel. Release the front wheel. Repeat steps a through d several times until all the marks come to rest at the same spot. NOTE: Start with the lightest weight. If the heavy spot does not stay in that position, install a heavier weight.

Repeat steps b and c until the front wheel is balanced. Turn the front wheel and make sure that it stays at each position shown. If the front wheel does not remain stationary at all of the positions, rebalance it. Brake caliper Locknut left and right Adjusting bolt left and right Wheel axle nut Washer Rear wheel axle Left adjusting block Right adjusting block Rear wheel Brake caliper bracket. NOTE: Make sure that the tapered side of the right adjusting block faces the wheel.

For installation, reverse the removal procedure. Remove the self-locking nuts and the rear wheel sprocket. Clean the rear wheel drive hub with a clean cloth, especially the surfaces that contact the sprocket. Install the new rear wheel sprocket. NOTE: Tighten the self-locking nuts in stages and in a crisscross pattern. The following procedure applies to both of the front brake calipers. NOTE: When replacing the brake pads, it is not necessary to disconnect the brake hose or disassemble the brake caliper.

Brake pad wear limit 0. Put the other end of the hose into an open container. Loosen the bleed screw and push the brake caliper pistons into the brake caliper with your finger. Tighten the bleed screw. Install a new brake pad shim onto each new brake pads. Install new brake pads and a new brake pad spring. NOTE: The arrow a on the brake pad spring must point in the direction of disc rotation.

Brake fluid reservoir cap stopper 1 Brake fluid reservoir cap 1 Brake fluid reservoir diaphragm 1 holder Brake fluid reservoir diaphragm 1 Brake fluid reservoir 1 Brake fluid reservoir hose 1 Hose joint 1 Union bolt 1 Copper washer 2 Brake hose 1 Brake master cylinder 1 For installation, reverse the removal procedure.

Recommended brake fluid DOT 4. New T. Brake pad clip 4 Brake pad pin 2 Brake pad spring 1 Brake pad 2 Brake caliper piston 2 Brake caliper piston seal 4 Bleed screw 2 For assembly, reverse the disassembly procedure. NOTE: Before disassembling either brake caliper, drain the brake fluid from the entire brake system.

Secure the right side brake caliper pistons with a piece of wood a. Blow compressed air into the brake hose joint opening b to force out the left side pistons from the brake caliper.

Remove the brake caliper piston seals. Repeat the previous steps to force out the right side pistons from the brake caliper. Secure the right side brake caliper piston with a piece of wood a. Blow compressed air into the brake hose joint opening b to force out the left side piston from the brake caliper.

Repeat the previous steps to force out the right side piston from the brake caliper. Front cowling inner panels Front fender Upper bracket pinch bolt Cap bolt Handlebar pinch bolt Lower bracket pinch bolt Front fork leg. The following procedure applies to both of the front fork legs.

Press down on the spacer with the fork spring compressor 4. Install the rod holder 5 between the nut 3 and the spacer 2. Fork spring compressor Rod holder Loosen the nut. Remove the cap bolt. Remove the rod holder and fork spring compressor. Remove the spacer and nut. Damper rod holder 7 – Spring free length limit mm. Be careful not to damage the inner tube. NOTE: While holding the damper rod with the damper rod holder 2, tighten the damper rod assembly bolt.

Damper rod holder 4. Fully compress the front fork leg. Other oils may have an adverse effect on front fork performance. After filling the front fork leg, slowly stroke the damper rod 1 up and down at least ten times to distribute the fork oil. NOTE: Be sure to stroke the damper rod slowly because the fork oil may spurt out. NOTE: Be careful not to stroke the inner tube over mm as this will cause air to enter. If the inner tube is stroked more than mm, repeat steps 12 and Before measuring the fork oil level, wait ten minutes until the oil has settled and the air bubbles have dispersed.

NOTE: Be sure to bleed the front fork leg of any residual air. Front fork leg oil level from the top of the inner tube, with the inner tube fully compressed, and without the spring 78 mm.

Install the rod puller and adapter onto the damper rod. Rod puller Adapter d. Install the fork spring, spring seat, and spacer. Press down on the spacer with the fork spring compressor 7. Pull up the rod puller and install the rod holder 8 between the nut 1 and the spacer 4. Fork spring compressor Rod holder g. Remove the rod puller and adapter. Install the nut 1 and position it as specified b. Distance b 11 mm i. Install the damper adjusting rod and cap bolt, and then finger tighten the cap bolt.

Hold the cap bolt and tighten the nut to specification. NOTE: Make sure that the inner fork tube is flush with the top of the handlebar holder. Apply a thin coat of rubber adhesive onto the end of the left handlebar. Slide the handlebar grip over the end of the left handlebar. Wipe off any excess rubber adhesive with a clean rag. Front fork legs Main switch coupler Upper bracket bolt Left handlebar assembly Right handlebar assembly Steering stem nut Upper bracket Lower bracket panel Brake hose holder bolt Lock washer Upper ring nut Rubber washer.

Remove the bearing race from the lower bracket with a floor chisel 2 and hammer. Install a new dust seal and new bearing races. NOTE: Temporarily tighten the steering stem nut.

NOTE: Temporarily tighten the upper and lower bracket pinch bolts, and handlebar pinch bolts. Before handling the rear shock absorber or gas cylinder, read and make sure you understand the following information. The manufacturer cannot be held responsible for property damage or personal injury that may result from improper handling of the rear shock absorber and gas cylinder. High heat can cause an explosion due to excessive gas pressure.

If the rear shock absorber, gas cylinder or both are damaged, damping performance will suffer. To release the gas pressure, press on the gas valve needle with a suitable tool as shown, until all of the gas is released the hissing has stopped.

NOTE: Before removing the drive sprocket, drive chain, and rear wheel, measure the drive chain slack and the length of a tenlink section of the drive chain. If the swingarm side play is out of specification, check the spacers, bearings, washers, and dust covers. Swingarm side play at the end of the swingarm 1. If swingarm vertical movement is not smooth or if there is binding, check the spacers, bearings, washers, and dust covers.

NOTE: If the swingarm must be replaced, the drive chain must be cut with a drive chain cutter. Wipe the drive chain with a clean cloth. Put the drive chain in kerosine and remove any remaining dirt. Never use highpressure water or air, steam, gasoline, certain solvents e. A coarse brush can also damage the O-rings.

When this light comes on, fill the fuel tank at the first opportunity. If this symbol flashes, stop the engine immediately and fill it with oil to the specified level. The following chart shows the conditions of the indicator light, symbol and temperature display in accordance with the coolant temperature. NOTE: Even if the oil is filled to the specified level, the warning light may flicker when riding on a slope or during sudden acceleration or deceleration, but this is normal. Stop the motorcycle and allow it to idle until Symbol and tem- the coolant temperature perature flashes goes down.

Odometer and trip meters Use the trip meters to estimate how far you can ride on a tank of fuel. Use the fuel reserve trip meter to see the distance traveled from when the fuel level dropped to the reserve level.

To set the clock: 1. If the continuity reading is incorrect, check the wiring connections and if necessary, replace the switch. Always insert the probes from the opposite end of the coupler, taking care not to loosen or damage the leads.

The terminal connections for switches e. The switch positions a are shown in the far left column and the switch lead colors b are shown in the top row in the switch illustration. The majority of these bulbs can be removed from their respective socket by turning them counterclockwise. Never pull the lead, otherwise it may be pulled out of the terminal in the coupler. Connect the tester positive probe to terminal 1 and the tester negative probe to terminal 2, and check the continuity.

Connect the tester positive probe to terminal 1 and the tester negative probe to terminal 3, and check the continuity. If either of the readings indicate no continuity, replace the bulb.

Pocket tester NOTE: Check each bulb socket for continuity in the same manner as described in the bulb section; however, note the following. Install a good bulb into the bulb socket.

Connect the pocket tester probes to the respective leads of the bulb socket. Check the bulb socket for continuity. If any of the readings indicate no continuity, replace the bulb socket. Disconnect the meter assembly coupler meter assembly side. Connect two jumper leads 1 from the battery terminals to the respective coupler terminals as shown. When the jumper leads are connected to the terminals the respective LED should illuminate.

Check: 1. Spark plugs The following procedure applies to all of the spark plugs. The following procedure applies to all of the spark plugs. Disconnect the spark plug cap from the spark plug. Connect the ignition checker 1 as shown. Measure the ignition spark gap a. Crank the engine by pushing the start switch and gradually increase the spark gap until a misfire occurs.

Ignition coil resistance The following procedure applies to all of the ignition coils. The following procedure applies to all of the spark plug caps. The starting circuit cutoff relay prevents the starter motor from operating when neither of these conditions has been met. In this instance, the starting circuit cutoff relay is open so current cannot reach the starter motor. When at least one of the above conditions has been met the starting circuit cutoff relay is closed and the engine can be started by pressing the start switch.

Starter motor front cover 1 Lock washer 1 Oil seal 1 Bearing 1 Washer set 1 Starter motor rear cover 1 Washer set 1 Armature assembly 1 Brush seat along with the brushes 1 Brush holder along with the brushes 1 O-ring 2 Starter motor yoke 1 For assembly, reverse the disassembly procedure. Mica undercut 0. Measure the armature assembly resistances with the pocket tester.

Pocket tester Armature assembly Commutator resistance 1 0. If any resistance is out of specification, replace the starter motor. Brush spring force 7. NOTE: Align the match marks a on the starter motor yoke with the match marks b on the front and rear covers. Stator coil resistance 0. Any of the following fail to light: headlight, high beam indicator light, taillight, auxiliary light or meter light. Open-circuit voltage A meter light fails to come on.

NO The wiring circuit from the main switch to the headlight coupler is faulty and must be repaired. The wiring circuit from the main switch to the meter assembly coupler is faulty and must be repaired.

NO The wiring circuit from the main switch to the auxiliary light connectors is faulty and must be repaired. Replace the fuse -s. YES Repair or replace the horn. NO Replace the left handlebar switch.

The turn signal relay is faulty and must be replaced. NO The wiring circuit from the main switch to the turn signal relay coupler turn signal relay side is faulty and must be repaired. The wiring circuit from the turn signal switch to the turn signal light connector is faulty and must be repaired.

The wiring circuit from the main switch to the meter light bulb coupler is faulty and must be repaired. Voltage Connect the pocket tester DC 20V to the meter assembly coupler wire harness side as shown.

NO The wiring circuit from the main switch to the meter assembly coupler is faulty and must be repaired. NO The wiring circuit from the main switch to the radiator fan motor coupler is faulty and must be repaired. If the thermo switch is dropped, replace it. Handle the temperature sender with special care. Never subject the temperature sender to strong shocks. If the temperature sender is dropped, replace it. Therefore, make sure that the engine is completely cool before performing the following test.

Fill the fuel tank. Put the end of the fuel hose into an open container. Connect the battery 12V to the fuel pump coupler as shown. If fuel flows out of the fuel hose, the fuel pump is OK. If fuel does not flow, replace the fuel pump. Procedure 1 Check: 1. Exup servomotor operation with the EXUP servomotor coupler connected to the wire harness 2.

Exup servomotor operation 4. Exup servomotor resistance 6. Procedure 1 1. EXUP servomotor resistance 5. The motorcycle can be ridden. The tachometer displays the condition code. When more than one item is being monitored, the tachometer needle displays the condition codes in ascending order, cycling through the sequence repeatedly. The tachometer starts to display the selfdiagnosis sequence. Exup 3. YES Replace the ignitor unit. It should be helpful, however, as a guide to basic troubleshooting.

Refer to the relative procedure in this manual for checks, adjustments, and replacement of parts. Worn brake pad Worn brake disc Air in hydraulic brake system Leaking brake fluid Faulty brake caliper piston seal.

Loose union bolt Damaged brake hose Oil or grease on the brake disc Oil or grease on the brake pad Incorrect brake fluid level.

Valve seat width Intake Exhaust Connecting rods Crankshaft-pin-to-big-end-bearing clearance Bearing color code. Electric starting system System type Starter motor Model manufacturer Power output Brushes Overall length Spring force Commutator resistance Commutator diameter Mica undercut Turn signal relay Relay type Model manufacturer Self-cancelling device built-in Turn signal blinking frequency Wattage.

Lower ring nut Engine mounting Front mounting bolts Rear upper mounting bolt Rear under mounting bolts Pinch bolts Exhaust pipe bracket Rear master cylinder. NOTE: 1. First, tighten the ring nut to approximately 18 Nm 1. A Properly insert the meter assembly coupler and rubber boot into the meter assembly.

B Route the meter assembly lead through the left side of the headlight housing. C The speedometer lead with not be tighten. D Install the headlight relays onto the headlight housing bridge.

E Connect to the right front turn signal connectors. F Route the turn signal leads upper the headlight housing boss. H Fasten the wire harness to the headlight housing boss with a plastic locking tie. I Route the headlight lead through the plastic guide. J Route the throttle cable to the front side of the brake hose. K Route the clutch cable behind the front fork leg.

L Make sure that the horn leads face out. M Route the throttle cables and right handlebar switch lead between the lower bracket and steering cover. O Route the right handlebar switch lead behind the throttle cables. P Route the right handlebar switch lead in front of the throttle cables. Thermostat assembly breather hose Radiator inlet hose Coolant reservoir breather hose Clutch cable Pickup coil lead A Fasten the starter motor lead to the flame which is just before the side cover stay 0 5 mm with a plastic clamp.

C Route the rollover-valve-to-fuel-tank hose to the inside of the fuel hose California only. D Route the coolant reservoir breather hose over the timing chain tensioner.

E Insert the plastic clip through the hole in the plastic frame panel and then fasten the wire harness and coolant reservoir breather hose with it. F Route the clutch cable between the radiator bracket and frame and in front of the thermostat assembly breather hose.

G Route the clutch cable to the inside of the radiator inlet hose. Fuel tank overflow hose and fuel tank breather hose Drive chain sprocket cover Coolant hose EXUP servomotor A Route the air filter case breather hose and air induction system hose to the inside of the wire harness. B Through the air cleaner drain hose, coolant reservoir tank breather, fuel tank breather hose, fuel tank over flow hose, air induction system hose and air induction system vacuum hose outside of the AC magneto lead.

Then, clamp all of them at just behind of the air induction system protector and air induction system vacuum hose protector, moreover at under the three sides pipe.

To the connector cover. J Route the sidestand switch lead and oil level switch Route the seat lock cable over the wire harness. Fasten the wire harness with a plastic clamp.

K Do not crush the water pump breather hose and Make sure the rear flasher light lead coupler and plastic clip. L Pass the fuel tank breather hose and the air filter G Route the rear turn signal lead through the hole in the drain hose through the steel clamps and then after upper rear fender.

I Fasten the sidestand switch lead, engine oil level M Route the engine oil level switch lead and sideswitch lead, and water pump breather hose with a stand switch lead inside the coolant hose. R No hose must be inserted into the under cowling. S O Pass the air filter drain hose and the coolant reservoir hose through the inside of the coolant hose and route the leading ends to the bottom of the T coolant hose.

The leading ends must not protrude from the under cowling. U P Fasten the air filter drain hose, coolant hose, cool- V ant reservoir tank breather hose, fuel tank breather hose, fuel tank drain hose and air induction system W hose at the steel clamp.

To the air filter. To the fuel tank. Insert the fuel tank breather hose into a back side nipple of fuel tank. The fuel tank nipple and the fuel tank breather hose have each white mark. Insert the fuel tank over flow hose into a front side nipple of fuel tank. To the air vent surge tank. Clamp under a three sides pipe. B Route the neutral switch lead direct to upper right side.

Headlight sub-wire harness Left handlebar switch lead Main switch lead Starter cable Right handlebar switch coupler Throttle cables Engine air vent hose EXUP servomotor coupler Air vent surge tank Starter motor lead Pickup coil coupler Fuel pump coupler. Neutral switch connector Battery negative lead Rear brake switch coupler Speed sensor coupler EXUP cable Fuel tank overflow hose Fuel tank breather hose except for California Tail light lead Rear flasher light lead Crankcase breather hose Generator coupler Sidestand switch coupler.

B Route the horn lead over the horn bracket and make sure that the lead has no slack. C Do not cross the throttle cables and right handlebar switch lead. D Route the thermo switch lead through the steel band on the radiator. E Fasten the main harness and thermo switch lead with a plastic clamp. Insert the plastic clamp into the hole on the frame. F Route the ignition coil sub-wire harness under the throttle position sensor.

G To the carburetor. H Route the coolant reservoir tank breather hose upper the air vent surge tank. I Fasten the wire harness and ignition coil subwire harness with a plastic clamp. J Route the idle adjust cable upper the ground lead. K Fasten the fuel pump lead, speed sensor lead, neutral switch lead, rear brake light lead, fuel sender lead, starter motor lead and EXUP cable with a plastic clamp.

L Fasten the fuel pump lead, speed sensor lead, tank breather hose have each white mark. M mm 4. O To the fuel cock. Q Insert the fuel tank over flow hose into a front side W Fasten the rear flasher light lead and taillight lead nipple of fuel tank. Route the rear flasher light R Insert the fuel tank breather hose into a back side lead and taillight lead in the hole on the taillight nipple of fuel tank. The fuel tank nipple and the fuel bracket. Y Position the ground coupler over the main harness.

Z Route the ground lead under the starter relay lead. Route the clamp end to outside, and insert it between wire harness and fender. Clamp the battery negative lead with a white tape mark. Fasten the main harness and fan motor lead with a plastic clamp. The clamp position. Connect the couplers of the same color. Check operation, fluid level and vehicle for fluid leakage.

Correct accordingly. Replace brake pads if necessary. Check swingarm pivoting point for play. Lubricate with lithium soap base grease. Check chain slack. Adjust if necessary. Apply: S sealant onto the crankcase mating surfaces and the groove a of the oil baffle plate Yamaha bond No. Install: S lower crankcase 1 onto the upper crankcase 2 CAUTION: Before tightening the crankcase bolts, make sure that the transmission gears shift cor- rectly when the shift drum assembly is turned by hand.

Radiator inlet hose Oil cooler outlet hose Disconnect. When there is negative pressure at the exhaust port, the reed valve opens, allowing secondary air to flow into the exhaust port. Check: S hoses Loose connection! Connect properly. NOTE: discs Place the motorcycle on a suitable stand Lubricate: S wheel axle S oil seal lips Recommended lubricant Lithium soap base grease 2.

Install: S brake discs 1 18 Nm 1. Page Electrical Instrument Functions 3. Push the start switch. If the warning light does not come on while pushing the start switch, have a Yamaha dealer check the electrical circuit. NOTE: This model is equipped with a selfdiagnosis de- vice for the fuel level warning light circuit. Page Coolant Temperature Warning Light 3. To set the clock: 1. Starter motor rear cover Bearing Starter motor yoke O-ring Armature assembly Brush Brush holder Starter motor front cover Bearing For assembly, reverse the disassembly procedure Check: S commutator Dirt!

Clean with grit sandpaper. Measure: S commutator diameter a Out of specification! Replace the starter motor. Measure: S mica undercut a Out of specification!

Scrape the mica to the proper measurement with a hacksaw blade Measure: S brush length a Out of specification! Replace the brushes as a set. Measure: S brush spring force Out of specification! Replace the brush springs as a set. Brush spring force 5. Battery S The radiator fan motor fails to turn. S Check the condition of the battery. Thermo unit 5. Fan motor relay S Disconnect the fan motor relay coupler.

S Remove the thermo unit from the radiator. S Connect the pocket tester S Connect the pocket tester 1 and bat- 1 to the ther- tery 12V to the fan motor relay coupler as mo unit Replace the thermo unit. EB 8. This circuit is OK. This manual is also suitable for: yzf-r1m. Print page 1 Print document 78 pages. Rename the bookmark. Delete bookmark? Cancel Delete.

Delete from my manuals?

 
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