Yamaha '09 YZF-R1 Kit Manual Download Page 68

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NUT, RING X
CYLINDER
HEAD

90179-08410

NUT

M8 x 1.25

20±2
(2.0±0.2)

EX. PIPE
(DIFFUSER) X
MUFFLER

90105-08063

BOLT,
FLANGE

M8 x 1.25

20±2
(2.0±0.2)

Install EX. PIPE
ASSY

95812-08040

BOLT,
FLANGE

M8 x 1.25

20±2
(2.0±0.2)

Install WIRE
PULLEY
DOUBLE NUT

14B-1133E-

14B-1133F-

WIRE,
PULLEY,1
WIRE,
PULLEY,2

M6 x 1.0

–

(0.5

–

0.7)

CATALYST
CONVERTER X
BRACKET,
REAR ARM

90111-08071

BOLT,
BUTTON
HEAD

M8 x 1.25

20±2
(2.0±0.2)

CATALYST
CONVERTER X
BRACKET
STAY

92014-08035

BOLT,
BUTTON
HEAD

M8 x 1.25

20±2
(2.0±0.2)

EX. PIPE ASSY
X CATALYST
CONVERTER

91314-06030

BOLT,
FLANGE

M6 x 1.0

10±2
(1.0±0.2)

Install
SERVOMOTOR

95022-06020

BOLT,
FLANGE
(SMALL
HEAD)

M6 x 1.0

10±2
(1.0±0.2)

MUFFLER X
REAR FRAME

95814-08045

BOLT,
FLANGE

M8 x 1.25

–

(1.8

–

2.8)

Install
MUFFLER
PROTECTOR

90111-06087

BOLT,
HEXAGON
SOCKET
HEAD

M6 x 1.0

10±2
(1.0±0.2)

Install
CATALYST
CONVERTER
PROTECTOR

90110-06200

BOLT,
HEXAGON
SOCKET
BUTTON

M6 x 1.0

6.5±1.5
(0.65±0.15)

Install PULLEY
COVER

90119-06115

BOLT,
HEXAGON
WITH
WASHER

M6 x 1.0

10±2
(1.0±0.2)

Install
DIFFUSER
COVER

90111-06095

BOLT,
HEXAGON
SOCKET
BUTTON

M6 x 1.0

7±1.5
(0.7±0.15)

Engine

To be tightened

Part No.

Part Name Thread dia.

pitch

Tightening

torque N•m

(kgf•m)

Q’ty

Remarks

Summary of Contents for '09 YZF-R1

Page 1: ... 09 YZF R1 KIT MANUAL The Performance Edge for excellent riders ...

Page 2: ... change without notice for improvement Parts List Symbols The star mark means that the part is included in the kit set and is a genuine Yamaha part Therefore you can easily purchase the part at any Yamaha part dealer when necessary The circle mark means that when needed the individual part is sold separately to the kit set Symbol Marks Particularly important information is distinguished in this ma...

Page 3: ...Sprocket Nut Set 4C8 A7463 70 27 2 2 Installing Chassis Parts 28 15 Oil Catcher Tank Set 14B C1707 70 28 16 Shock Absorber Rear 14B 22210 70 30 17 Spring Rear Shock 32 18 Front Fork ASSY 33 19 Spring Front Fork 35 20 Seat Cushion 13S 24713 70 39 21 Front Spare Wheel ASS Y 4C8 25100 70 40 22 Rear Spare Wheel ASS Y 4C8 25300 70 41 23 Throttle Set 14B C6300 70 42 24 Throttle Set 14B C6300 80 44 25 Tu...

Page 4: ...Compression ratio 12 8 1 13 2 1 will result from 0 2mm cylinder head surface grinding 12 7 1 Valve timing event angle INT 110 105 EXT 110 105 Squish height 0 65 mm Minimum 0 775 mm Minimum Clearance between valve and piston INT 1 0 mm ATDC10 1 16 mm ATDC10 EXT 2 0 mm BTDC10 2 14 mm BTDC10 Valve tappet clearance INT 0 17 0 23 mm 0 11 0 20 mm EXT 0 27 0 33 mm 0 21 0 25 mm ...

Page 5: ...2 4 5VY 1165A 01 BOLT CONNECTING ROD SPECIAL 24 5 93450 18157 CIRCLIP 24 6 3P6 12129 00 SEAL VALVE STEM OIL 2 24 INT 7 4TE 12119 00 SEAL VALVE STEM OIL 24 EXT 8 14B 13414 70 GASKET STRAINER 3 OIL PAN ANTI STICK TYPE 9 14B 15451 70 GSKT CRANKCASE COVER 1 3 ACM ANTI STICK TYPE 10 14B 15461 70 GSKT CRANKCASE COVER 2 3 CLUTCH ANTI STICK TYPE 11 14B 15456 70 GSKT 1 3 PICK UP ANTI STICK TYPE 12 14B 1546...

Page 6: ...on is needed during installation on the following points 1 The tightening torque is 10 12 N m 1 0 1 2 kgf m 2 When not checking the torque tighten by rotating through 30 after manual tightening in the case of new plugs When reusing plugs tighten by rotating through 15 Parts List No PART No PART NAME Q TY REMARKS 1 14B 1119C 70 PLUG SPARK 4 NGK R0465B 10 15 30 Reused New gasket ...

Page 7: ...e standard head cylinder gasket thickness is 0 40 mm and the cylinder gasket thickness is 0 20 mm GASKET CYLINDER HEAD GASKET CYLINDER Parts List No PART No PART NAME Q TY REMARKS 1 14B 11181 70 GASKET CYLINDER HEAD 1 1 t 0 30 mm 2 14B 11181 80 GASKET CYLINDER HEAD 1 1 t 0 35 mm 3 14B 11351 70 GASKET CYLINDER 1 1 t 0 10 mm 4 14B 11351 80 GASKET CYLINDER 1 1 t 0 15 mm Stamping location Stamping loc...

Page 8: ...ANUAL NOTICE When using this camshaft use the valve spring set 14B A2110 70 Make sure to align the valve timing when the camshaft is assembled If otherwise no intended performance can be expected and more over the engine may be damaged Parts List No PART No PART NAME Q TY REMARKS 1 14B 12170 70 SHAFT CAM 1 1 INT 2 14B 12180 70 SHAFT CAM 2 1 EXT 90105 07006 14B 12176 00 2 1 USE THESE OVAL HOLES FOR...

Page 9: ...d when the camshaft is mounted from the kit NOTICE When using this valve spring use the camshafts 14B 12170 70 and 14B 12180 70 Parts List No PART No PART NAME Q TY REMARKS 1 14B 12113 70 SPRING 1 8 I D Color Blue INT 2 14B 12114 70 SPRING 2 8 I D Color Red EXT ...

Page 10: ... screws 25mm long 2 Installing the Supports Install the supports onto the levers Make sure to use the STD bush in the support hole Use the lever and bushing intended for a STD machine Parts List No PART No PART NAME Q TY REMARKS 1 PLATE L 1 2 PLATE R 1 3 PRIMARY FUNNEL 4 L 55mm 4 SUPPORT L 1 5 SUPPORT R 1 6 SHAFT ASSY 1 Short type Support L Lever Assembly Support R Bush Bush Lever ...

Page 11: ...Funnels Secure the primary funnel by screwing it into the plate TIP For installation of the plate and funnel apply a thin coat of grease to their screw threads For installation of the right hand funnel arrange the resin portion of the lever to be located above the funnel 5 Installing the Secondary Funnel Install the STD secondary funnel onto the lever assembly Holes for installation ...

Page 12: ...bly Install the shaft assembly that is shorter than the STD After fitting the assembly onto the ball joint on the motor side fit the white prism rod on the reverse side to the lever assembly clip Motor side Clip Ball joint Lever side ...

Page 13: ...iming by using the YMS software packed together with the kit ECU You can also control the STD funnel by using the YMS software This set is made by MG Competition For details of the specification please check with MG Competition TEL 33 0 4 50 25 59 96 FAX 33 0 4 50 25 59 98 Web http www mgcompetition fr ...

Page 14: ...tioning bands at the cabjoint The part has a collar to prevent over tightening In normal cases the part will not be tightened till it reaches to the collar Just manually tighten it Make sure to put a new band through a M5 x 0 8 tap before using it Parts List No PART No PART NAME Q TY REMARKS 1 CLAMP COMP 1 Right side 3 4 2 CLAMP COMP 1 Left side 1 2 2 1 Cut it off ...

Page 15: ...ate from inside 3 Install the plate 5SL 1482L 70 in replacement of the cap Apply liquid gasket to the plate 4 Remove the cylinder head cover and the four collars fitted to the cover Install the PIN 93608 16M16 5 After removing the hose connected to the air filter casing form the air cut off assembly insert the PLUG 90336 10020 onto the side of the air filter casing to close the opening Parts List ...

Page 16: ... 13 STD KIT 3 2 1 1 ...

Page 17: ... 14 9 Clutch Spring Set 4B1 A6330 70 The kit spring has 10 more installation load than the STD spring Parts List No PART No PART NAME Q TY REMARKS 1 4B1 16334 70 SPRING CLUTCH 6 1 ...

Page 18: ...utch Setting Set 4C8 A6377 70 Installing this part makes it possible to adjust the engine braking effect Parts List No PART No PART NAME Q TY REMARKS 1 4C8 16377 70 NUT LOCK 1 2 4B1 16391 70 SHIM 3 c a 2 1 b 52 8 53 4mm ...

Page 19: ...lutch setting set Recommended setting method To begin with the dimensions of the clutch are re set to the standard values For details please refer to the service manual published from YAMAHA MOTOR CO LTD When the slipper clutch setting sets are to be installed and the number of the SHIMs are to be three in stack the setting may be carried out according to the standard Spring may be selected from e...

Page 20: ...k torque limiter becomes effective Engine braking becomes less effective NOTICE When decreasing the number of spring to two the caution should be taken to surely use three pieces of SHIMs for the slipper clutch setting set If its number being less than the above the less load may be supported so as to exert serious influences on driving Decreasing the number of spring to one is not allowed Standar...

Page 21: ...PINION 1 BC 7 14B 17161 70 A GEAR 6TH PINION 1 A 7 14B 17161 80 B GEAR 6TH PINION 1 B 7 14B 17161 90 C GEAR 6TH PINION 1 C 8 14B 17402 70 DRIVE AXLE ASSY 1 9 14B 17421 00 AXLE DRIVE 1 10 93305 20605 BRG 1 11 90387 30012 COLLAR 1 12 14B 17211 70 A GEAR 1ST WHEEL 1 A 12 14B 17211 80 B GEAR 1ST WHEEL 1 B 12 14B 17211 90 C GEAR 1ST WHEEL 1 C 13 14B 17221 70 A GEAR 2ND WHEEL 1 A 13 14B 17221 80 B GERA ...

Page 22: ...he STD gear making it possible to select a gear adapted to the course Select the gear after referring to the speed table and the ratio table 17 14B 17261 70 A GEAR 6TH WHEEL 1 A 17 14B 17261 80 B GEAR 6TH WHEEL 1 BC Parts List No PART No PART NAME Q TY REMARKS ...

Page 23: ... 1st 38 15 2 533 34 14 2 429 33 14 2 357 37 16 2 313 2nd 33 16 2 063 32 15 2 133 32 16 2 000 31 16 1 938 3rd 37 21 1 762 31 17 1 824 33 19 1 737 29 18 1 611 4th 35 23 1 522 32 20 1 600 35 23 1 522 31 21 1 476 5th 30 22 1 364 28 19 1 474 31 22 1 409 30 22 1 364 6th 33 26 1 269 28 21 1 333 33 25 1 320 33 26 1 269 12 16 14 15 17 13 8 9 10 11 1 3 2 6 5 7 4 ...

Page 24: ...B 17231 80 B 33 14B 3WB C 1 611 18 14B 3PC 14B 17231 90 C 29 14B 3WC 4th A 1 600 20 14B 4PA 14B 17241 70 A 32 14B 4WA B 1 522 23 14B 4PB 14B 17241 80 B 35 14B 4WB C 1 476 21 14B 4PC 14B 17241 90 C 31 14B 4WC 5th A 1 474 14B 17151 70 A 19 14B 5PA 14B 17251 70 A 28 14B 5WA B 1 409 14B 17151 80 B 22 14B 5PBC 14B 17251 80 B 31 14B 5WB C 1 364 14B 17151 80 B 22 14B 5PBC 14B 17251 90 C 30 14B 5WC 6th A ...

Page 25: ... 215 0 213 8 211 1 210 2 206 2 205 6 201 6 201 3 197 1 192 8 188 7 B 19 33 1 737 257 4 251 2 245 4 242 2 239 8 236 5 234 5 231 0 229 4 227 1 225 7 224 5 221 7 220 7 216 5 215 9 211 6 211 3 206 9 202 4 198 1 C 18 29 1 611 277 5 270 9 264 6 261 1 258 5 254 9 252 8 249 0 247 3 244 8 243 3 242 0 239 0 237 9 233 4 232 8 228 1 227 8 223 1 218 2 213 6 4th A 20 32 1 600 279 4 272 7 266 4 263 0 260 3 256 7...

Page 26: ... WASHER 6 23 93440 28184 CIRCLIP 10 24 90387 25023 COLLAR 3 25 90214 25004 WASHER CLAW 3 26 90214 25003 WASHER CLAW 3 27 90387 31003 COLLAR 3 28 90209 28008 WASHER 9 29 93440 31187 CIRCLIP 15 30 90387 28004 COLLAR 6 31 90214 29002 WASHER CLAW 3 32 90214 28002 WASHER CLAW 3 33 90387 25008 COLLAR 3 34 93102 40330 SEAL OIL 3 35 93440 62032 CIRCLIP 5 36 90201 257H0 WASHER PLAIN 3 37 93306 27208 BRG 3 ...

Page 27: ... 24 36 38 33 29 29 34 21 22 22 24 23 23 35 25 26 37 28 30 32 31 30 28 28 29 27 ...

Page 28: ...spline threads Circlip Shaft Edge PortionR Edge Detail of installation of washer Detail of installation of washer Shaft Washer Washer Matching mark Matching mark Portion R Washer Gear The seal side should face outward one side seal bearing and press in the bearing cup all the way into the case until it touches bottom Points to be careful of the oil seal assembly The convex part on the oil seal sho...

Page 29: ... to 520 in relation to the STD one NOTICE When using this drive sprocket use the sprocket nut of the kit Parts List No PART No PART NAME Q TY REMARKS 1 4XV 17460 75 SPROCKET DRIVE 1 15T 520SIZE 2 4XV 17460 76 SPROCKET DRIVE 1 16T 520SIZE 3 4XV 17460 77 SPROCKET DRIVE 1 17T 520SIZE ...

Page 30: ...sprocket nut uses a bending type of lock washer instead of the STD caulking type NOTICE When using this sprocket nut use the drive sprocket of the kit Parts List No PART No PART NAME Q TY REMARKS 1 4C8 17463 70 NUT 1 2 90215 30233 WASHER LOCK 1 ...

Page 31: ...ase from the crankcase 3 Install the oil catcher tank and breather hose from the kit as shown Install at the same positions where the coolant reservoir were removed NOTICE Change the clip direction so it does not contact the wire harness Parts List No PART No PART NAME Q TY REMARKS 1 14B 21707 70 OIL TANK COMP 1 2 90467 18172 CLIP 4 3 14B 15373 70 PIPE BREATHER 1 4 14B 15393 70 PIPE BREATHER 2 1 5...

Page 32: ... 29 1 N 2 3 4 5 6 made in japan 8 6 5 7 Crankcase Crankcase 3 2 2 2 4 1 E G ...

Page 33: ...wise to increase the preload and anticlockwise to reduce the preload The adjustment range is 8mm 0 5mm turn Shipping position Tightened 8 turns from the preload minimum position Parts List No PART No PART NAME Q TY REMARKS 1 14B 22210 70 SHOCK ABSORBER Rr 1 98 N mm Low speed compression damping adjustor bolt width 4mm hexagonal hole High speed compression damping adjustor bolt width 12mm hexagonal...

Page 34: ...se the damping force and anticlockwise to reduce the damping force The adjustment range is 1 to 20 steps back from the lightly tightened adjustor position Shipping position 10 steps back from the tightened adjustor position NOTICE When tightening the adjustor do it lightly Over tightening the adjustor can damage it At High Speeds Turn clockwise to increase the damping force and anticlockwise to re...

Page 35: ...ength diameter and rate For spring replacement see the 14B STD Service Manual The spring rate of the standard rear suspension is 98 1 N mm Parts List No PART No PART NAME Q TY REMARKS 1 14B 22222 70 SPRG Rr SHOCK 1 108 N mm Identifying stamp 159 5 55 108 2 14B 22222 75 SPRG Rr SHOCK 1 103 N mm Identifying stamp 159 5 55 103 3 14B 22222 80 SPRG Rr SHOCK 1 98N mm Identifying stamp 159 5 55 98 ...

Page 36: ...compression and rebound damping force Preload Adjustment Method Turn clockwise to increase the preload and anticlockwise to reduce the preload The adjustment range is 15mm 1mm turn Shipping position Tightened 5 turns from the preload minimum position Parts List No PART No PART NAME Q TY REMARKS 1 14B 23102 70 Fr FORK ASSY LH 1 10 0 N mm 2 14B 23103 70 Fr FORK ASSY RH 1 10 0 N mm Compression dampin...

Page 37: ...om the adjustor s clockwise lightly tightened position Compression 1 to 25 steps back from the adjustor s clockwise lightly tightened position Shipping position Rebound 10 steps back from the tightened adjustor position Compression 10 steps back from the tightened adjustor position NOTICE When tightening the adjustor do it lightly Over tightening the adjustor can damage it ...

Page 38: ...you do not need to replace the preload tube Use the original tube fitted to the fork TIP A spanner SPECIAL TOOLS and rod SPECIAL TOOLS are supplied with the front fork 14B 23102 70 Use Yamaha M1 suspension oil Parts List No PART No PART NAME Q TY REMARKS 1 14B 23141 70 SPRG Fr FORK 1 11 0 N mm Identifying slits 3 2 14B 23141 75 SPRG Fr FORK 1 10 5 N mm Identifying slits 2 3 14B 23141 80 SPRG Fr FO...

Page 39: ... until the dust seal touches the upper surface of the axle bracket 3 Insert the spanner SPECIAL TOOLS into the notch of the spring seat upper and clamp the 14mm special nut 4 Use a 14mm box spanner on the preload adjustor to remove the cap bolt assembly NOTICE Do not remove the spanner SPECIAL TOOLS while doing this Rebound damping adjustor Preload adjustor Fork bolt Axle bracket Spanner SPECIAL T...

Page 40: ...e rod SPECIAL TOOLS firmly and remove the spanner SPECIAL TOOLS NOTICE Be very careful to apply downward pressure on the rod SPECIAL TOOLS when you remove the spanner SPECIAL TOOLS 7 Remove the spring seat upper and preload tube before removing the rod SPECIAL TOOLS Rod SPECIAL TOOLS ...

Page 41: ...ve the spanner SPECIAL TOOLS 9 Press the rod downwards before adjusting the oil level Oil level in Shipping state With the spring removed and the outer tube and rod lowered 160mm from the top of the outer tube 10 Reassemble the parts after oil level adjustment by following the disassembly procedure in reverse Washer Special nut Spring guide Tightening torque 20N m ...

Page 42: ... 39 20 Seat Cushion 13S 24713 70 Anti slip seat Cut to any size for use Parts List No PART No PART NAME Q TY REMARKS 1 13S 24713 70 CUSHION SEAT 1 ...

Page 43: ...8 25100 70 This kit does not include a tire This part is an assembly of bearings spacers and an air valve in a STD wheel Parts List No PART No PART NAME Q TY REMARKS 1 4C8 25160 00 CAST WHEEL ASSY 1 MAT BLACK 2 93900 00030 VALVE RIM 1 ...

Page 44: ...4C8 25300 70 This kit does not include a tire This part is an assembly of bearings spacers and an air valve in a STD wheel Parts List No PART No PART NAME Q TY REMARKS 1 4C8 25370 00 WHEEL CAST 1 MAT BLACK 2 93900 00030 VALVE RIM 1 ...

Page 45: ...TLE 1 1 Grip side Pull side Stamp 14B 70 1 Plated color Black 6 14B 26312 70 WIRE THROTTLE 2 1 Grip side Release side Stamp 14B 70 2 Plated color White 7 14B 26313 70 WIRE THROTTLE 3 1 Engine side Pull side Stamp 14B 70 3 Plated color Black 8 14B 2631J 70 WIRE THROTTLE 4 1 Engine side Release side Stamp 14B 70 4 Plated color White 9 2C0 26261 70 CYLINDER 2 10 5FL 26244 70 SLIDER 2 11 2C0 2639E 70 ...

Page 46: ... side Engine side Pull side Black Pull side Black Release side White Release side White Release side White Throttle body 12 14 13 8 9 10 11 1 3 2 6 5 7 4 FWD Machining off the boss Scrap away CAP GRIP UPPER of the kit as shown above ...

Page 47: ...RKS 1 2C0 26281 70 CAP GRIP UPPER 1 2 5FL 26282 00 CAP GRIP UNDER 1 3 5SL 26243 71 TUBE GUIDE 1 Linear type 4 2C0 26391 70 CLIP WIRE 1 1 5 14B 26301 70 THROTTLE WIRE ASSY 1 1 Pull side Stamp 14B 80 1 Plated color Black 6 14B 26302 70 THROTTLE WIRE ASSY 2 1 Release side Stamp 14B 80 2 Plated color White 7 90201 261L1 WASHER PLAIN 1 8 91314 05020 BOLT HEX SOCKET HEAD 2 9 91314 05008 BOLT HEX SOCKET ...

Page 48: ...ull side Black Pull side Black Release side White Release side White Pull side Black Air filtre side Engine side Release side White FWD Machining off the boss Scrap away CAP GRIP UPPER of the kit as shown above Throttle body ...

Page 49: ...d is 58 According to this the easy operability has been realized through controlling the throttle body opening at an initial stage of the throttle grip operation the stage of which is difficult to control as that of the STD while keeping the operability full opening performance during racing Parts List No PART No PART NAME Q TY REMARKS 1 5VY 26243 80 TUBE GUIDE 1 Progressive type Throttle body ope...

Page 50: ...fication just remove two couplers located at the lower left of the kit harness fuel tank See the figure below Setting up Details SB specification Kit cam shaft and Recommended muffler ST specification Recommended muffler Recommended muffler Made by Akrapovic For details of the specification please access the website Web http www akrapovic exhaust com NOTICE Do not use the ECU of this set for any o...

Page 51: ... the cable to the PC for the first time it is necessary to install the USB driver Refer to the USB Driver Installation Manual provided on the 8 cm CD for details on how to install the USB driver The product vendor ID and product ID are provided by the Hamamatsu TOA Electronics Inc Vendor ID 6837 Product ID 9001 Parts List No PART No PART NAME Q TY REMARKS 1 13S 8533A 70 CABLE INTERFACE 1 USB 2 13S...

Page 52: ...mp C 06 Water temperature sensor Water Temp C 07 Vehicle speed sensor Speed Signal 08 Overturn sensor Lean Angle Signal V 09 Monitor voltage System Voltage V 13 Throttle sensor 2 TPS 2 deg 14 Accelerator sensor 1 APS 1 deg 15 Accelerator sensor 2 APS 2 deg 30 Ignition coil 1 31 Ignition coil 2 32 Ignition coil 3 33 Ignition coil 4 34 Intake funnel 36 Injector primary 1 37 Injector primary 2 38 Inj...

Page 53: ...21 Water temperature sensor malfunctions open circuit short circuit 22 Intake temperature sensor malfunctions open circuit short circuit 23 Atmospheric pressure sensor malfunctions open circuit short circuit 33 Ignition coil 1 malfunctions open circuit 34 Ignition coil 2 malfunctions open circuit 35 Ignition coil 3 malfunctions open circuit 36 Ignition coil 4 malfunctions open circuit 39 Injector ...

Page 54: ... not used removing its coupler will pose no problem Parts List No PART No PART NAME Q TY REMARKS 1 14B 82590 70 WIRE HARNESS ASSY 1 2 5GF 83976 00 SW HANDLE 1 1 PIT ROAD LIMITER 3 14B 83976 70 SW HANDLE 1 1 Map select 4 2C0 82509 70 WIRE SUB LEAD 1 5 4C8 82188 70 RESISTOR ASSY 1 Finished with joint in Wire Harness 6 14B 2128A 70 BRKT REGULATOR 1 1 7 90480 13003 GROMMET 2 8 90560 06201 SPACER 2 9 9...

Page 55: ...wire harness from the kit by reference to the service manual 3 Pass the wire harness through the hole in the cable holder side and secure it with a clamp at the location indicated Align the clamping position with the purple taping on the wire harness To meter Cable holder Clamp Wire harness ...

Page 56: ... 53 NOTICE When the oil catcher tank is in use change the direction of the hose clip so it won t touch the wire harness Wire harness ...

Page 57: ...from the ACM is designed to be so long that for routing it enough care should be taken not to allow it to hang out of the chassis or to interfere with other parts To ACM Rectifier Regulator To wire harness ECU Wire harness ...

Page 58: ... fixing for BRKT5 seat 2 Install BRKT5 with bolt and washer at the location where the STD mudguard was installed 3 Install BRKT4 to BRKT5 with bolt collar and grommet 4 Install plug to BRKT4 5 Secure the ECU with band 10 CUT 43 7 58 4 57 10 16 17 11 10 18 13 12 14 15 12 10 11 13 18 14 15 17 16 ECU ...

Page 59: ...egulator to the catcher tank from the kit using the STD chassis bolts 3 In case the oil catcher tank is not used from the kit install the rectifier regulator using the supplied bracket grommet spacer and bolt In case the oil catcher tank is used In case the oil catcher tank is not used 6 7 8 9 STD Rectifier Regulator Oil catcher tank STD 6 7 8 9 Rectifier Regulator ...

Page 60: ...p select and pit road limiter to be used See diagram 1 The switch accompanying the assembly functions as the main switch Use the 3 prong coupler in front with the red wire attached as the main switch See diagram 2 Fitting it turns the power on and removing it turns the power off NOTICE Be careful not to pull the wire too strongly Main switch Pit road limiter Starter switch Diagram 1 Engine stop sw...

Page 61: ... diagram 4 However if the resistor assembly is not installed there is the possibility that the shifter switch will operate incorrectly in rainy weather See diagram 5 NOTICE Do not bend the resistor assembly It will cease to function if it is bent Install the switch to the 2 pin black coupler underneath the fuel tank Turning the switch ON cuts the ignition Digram 3 Starter switch Pit road limiter O...

Page 62: ...d the coupler for power white 2 prong Connecting them may cause a malfunction See diagram 6 This harness has a coupler that connects to the 2D made data logger For details of the specifications of the data logger please access the website Webhttp www 2d kit system com ...

Page 63: ...he headlight lights up on the Hi side The headlight and taillight circuits are independent of one another If the headlight is broken the taillight will not go out The switch 5GF 83976 00 lights only the rear light Parts List No PART No PART NAME Q TY REMARKS 1 14B 84359 70 CORD HEAD LIGHT 1 2 5JJ 81950 20 RELAY ASSY 1 3 5GF 83976 00 SW HANDLE 1 1 For emergency 4 5RT 83963 00 SW HANDLE 3 1 On off k...

Page 64: ...hem 2 Apply engine oil on the thread and flange of mounting bolts before using them 3 Using the included adhesive adhere the carbon cover to the crankcase cover Parts List No PART No PART NAME Q TY REMARKS 1 14B 81410 70 STATOR ASSY 1 2 14B 81450 70 ROTOR ASSY 1 3 14B 15411 70 COVER CRANKCASE 1 1 4 14B 15414 70 COVER 1 1 5 14B 1541H 70 BOND COVER 1 Adhesive 6 90149 06080 SCREW 4 7 14B 15451 70 GSK...

Page 65: ...AD 90179 10029 NUT M10 x 1 25 TURN OF NUT METHOD AXIAL FORCE TAR GET VALUE OF 43kN 5kN 8 FOR DETAILS SEE page 73 Tighten HEAD 90110 05315 BOLT HEXAGON SOCKET HEAD M6 x 1 0 12 2 1 2 0 2 2 CAP x HEAD 90105 06027 BOLT FLANGE M6 x 1 0 10 2 1 0 0 2 20 APPLY OIL TO SCREW THREAD AND BEARING SURFACE Tighten HEAD COVER 90109 066F0 BOLT M6 x 1 0 10 2 1 0 0 2 6 Embedded in HEAD Install EX PIPE 95612 08625 BO...

Page 66: ...0 0 2 2 Install PIPE 4 90110 06182 BOLT HEXAGON SOCKET HEAD M6 x 1 0 10 2 1 0 0 2 1 WATER PUMP SIDE Install PIPE 4 90110 06022 SCREW M6 x 1 0 10 2 1 0 0 2 1 RUBBER MOUNT SIDE Tighten HOSE 90450 38040 HOSE CLAMP ASSY REF 1 5 2 5 0 15 0 25 3 BREAKAGE OCCURS AT 4 5N m 90450 35001 3 Install PUMP DRIVING SPROCKET 90105 06066 BOLT FLANGE M6 x 1 0 15 2 1 5 0 2 1 DEGREASE SCREW THREAD Install PUMP 90110 0...

Page 67: ...1 20145 BOLT UNION M20 x 1 5 80 15 8 0 1 5 1 Install OIL CLEANER ASSY 5GH 13440 20 OIL CLEANER ASSY M20 x 1 5 17 2 1 7 0 2 1 APPLY GREASE TO O RING Install COVER STRAINER 90149 06079 SCREW M6 x 1 0 10 2 1 0 0 2 13 Install RELIEF VALVE 90110 06169 BOLT HEXAGON SOCKET HEAD M6 x 1 0 10 2 1 0 0 2 2 Install THROTTLE WIRE 14B 26302 00 BOLT ADJUST ING M6 x 1 0 3 5 5 5 0 35 0 55 2 JOINT ASSY X THROTTLE BO...

Page 68: ... 1 EX PIPE ASSY X CATALYST CONVERTER 91314 06030 BOLT FLANGE M6 x 1 0 10 2 1 0 0 2 1 Install SERVOMOTOR 95022 06020 BOLT FLANGE SMALL HEAD M6 x 1 0 10 2 1 0 0 2 1 MUFFLER X REAR FRAME 95814 08045 BOLT FLANGE M8 x 1 25 18 28 1 8 2 8 2 Install MUFFLER PROTECTOR 90111 06087 BOLT HEXAGON SOCKET HEAD M6 x 1 0 10 2 1 0 0 2 4 Install CATALYST CONVERTER PROTECTOR 90110 06200 BOLT HEXAGON SOCKET BUTTON M6 ...

Page 69: ...FLANGE M6 x 1 0 10 2 1 0 0 2 1 APPLY OIL TO BEARING SURFACE CRANKCASE 1 x CRANKCASE 2 95812 06060 BOLT FLANGE M6 x 1 0 10 2 1 0 0 2 6 APPLY OIL TO BOTH SCREW THREAD AND BEARING CRANKCASE 1 x CRANKCASE 2 95812 06050 BOLT FLANGE M6 x 1 0 10 2 1 0 0 2 7 APPLY OIL TO BOTH SCREW THREAD AND BEARING CRANKCASE 1 x CRANKCASE 2 95812 06040 BOLT FLANGE M6 x 1 0 10 2 1 0 0 2 4 APPLY OIL TO BOTH SCREW THREAD A...

Page 70: ...NOT TO OVER TIGHTEN MAIN GALLERY 1 36Y 15189 00 PLUG M16 x 1 5 8 2 0 8 0 2 2 TAKE CARE NOT TO OVER TIGHTEN MAIN GALLERY 2 4H7 15189 00 PLUG M20 x 1 5 8 2 0 8 0 2 1 TAKE CARE NOT TO OVER TIGHTEN Install HOLDER CLUTCH WIRE 90110 06340 BOLT M6 x 1 0 10 2 1 0 0 2 2 OIL RETURN PLUG 90340 12003 PLUG STRAIGHT SCREW M12 x 1 0 24 3 2 4 0 3 1 ACM LEAD 90110 06182 BOLT HEXAGON SOCKET HEAD M6 x 1 0 10 2 1 0 0...

Page 71: ...W CROSS RECESSE D COUN TERSUNK M6 x 1 0 12 2 1 2 0 2 3 CLAMP Install STOPPER SHIFT BAR and PLATE STOPPER 2 90149 06071 SCREW M6 x 1 0 10 2 1 0 0 2 2 Install STOPPER SCREW 1D7 18127 00 STOPPER SCREW M8 x 1 25 22 2 2 2 0 2 1 Install ROD SHIFT 90170 06228 NUT HEX AGON M6 x 1 0 6 5 1 5 0 65 0 15 1 Install ROD SHIFT 95304 06700 NUT HEX AGON M6 x 1 0 6 5 1 5 0 65 0 15 1 LEFT HAND SCREW Install JOINT ROD...

Page 72: ...Install SENSOR PRESSURE for atmospheric pressure 97707 50020 SCREW TRUSS HEAD TAP PING M5 x 0 8 6 8 0 6 0 8 2 Install PICKUP ASSY 90110 06168 BOLT HEXAGON SOCKET HEAD M6 x 1 0 10 2 1 0 0 2 2 Install OIL LEVEL SENSOR 95022 06016 BOLT FLANGE SMALL HEAD M6 x 1 0 10 2 1 0 0 2 2 APPLY GREASE TO O RING Install STARTER MOTOR 90109 06016 BOLT HEXAGON SOCKET HEAD M6 x 1 0 12 2 1 2 0 2 2 Install SPEED SENSO...

Page 73: ...d UNDER BRACKET 91314 08030 BOLT HEXAGON SOCKET HEAD M8 x 1 25 20 25 2 0 2 5 4 E G BRACKET FRONT LEFT 95817 12080 BOLT FLANGE M12 x 1 25 60 80 6 1 8 2 1 E G BRACKET FRONT RIGHT 90105 12062 BOLT FLANGE M12 x 1 25 60 80 6 1 8 2 1 E G BRACKET REAR UPPER 90179 10028 NUT M10 x 1 25 42 60 4 3 6 1 1 E G BRACKET REAR UNDER 90179 10028 NUT M10 x 1 25 42 60 4 3 6 1 1 ADJUST BOLT for E G BRACKET REAR 14B 214...

Page 74: ... 25 1 SCREW IN FROM THE LEFT SIDE 95602 10200 NUT U FLANGE M10 x 1 25 31 49 3 2 5 0 1 BRACKET UPPER FRAME 95602 16200 NUT U FLANGE M16 x 1 0 71 112 7 2 11 4 1 ADJUST NUT for CHAIN PULLER 95302 08600 NUT HEX AGON M8 x 1 25 12 19 1 2 1 9 2 FUEL TANK FUEL PUMP 90110 05028 BOLT HEXAGON SOCKET HEAD M5 x 0 8 3 5 0 3 0 5 6 FRONT STAY for FUEL TANK FRAME 95022 06030 BOLT FLANGE SMALL HEAD M6 x 1 0 5 8 0 5...

Page 75: ... M6 x 1 0 14 22 1 4 2 2 10 DISC BRAKE WHEEL REAR 90149 08009 SCREW M8 x 1 25 23 37 2 3 3 8 5 REAR WHEEL SPROCKET CLUTCH HUB 90185 10009 NUT SELF LOCKING M10 x 1 25 90 109 9 2 11 1 6 SPLIT BOLT for FRONT AXLE 91314 08035 BOLT HEXAGON SOCKET HEAD M8 x 1 25 18 23 1 8 2 3 4 For reference Tightening torque N m M5 0 8 4 5 7 0 M6 1 0 7 5 12 M8 1 25 18 28 M10 1 25 37 58 M10 1 25 68 108 Chassis To be tight...

Page 76: ...45 5 3 Retighten the bolts in the tightening sequence of 3 to 7 to a turn of nut angle of 135 5 4 Retighten the bolts in the tightening sequence of 8 and 9 to a turn of nut angle of 160 5 5 Retighten the bolts in the tightening sequence of 10 to a turn of nut angle of 135 5 TIP The numbers 1 to 10 show the sequence in which the bolts are tightened Apply engine oil to the bolt threads contact surfa...

Page 77: ... 56 61 60 at new Tightening torque for reference 35 0N m 3 5kg m 4 Tighten the bolts in the tightening sequence of 11 to 20 to 24 2N m 2 4 0 2kgf m 5 Tighten the bolts in the tightening sequence of 21 to 40 to 10 2N m 1 0 0 2kgf m TIP The numbers 1 to 40 show the sequence in which the bolts are tightened Apply engine oil to the bolt threads and both sides of the washers These numbers indicate the ...

Page 78: ... 75 ...

Page 79: ... 76 4 Headlight Cord Wiring Diagram ...

Page 80: ... 77 5 YZF R1 Wiring Diagram ...

Page 81: ...Published by YAMAHA MOTOR ENGINEERING co LTD ...

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Yamaha '09 YZF-R1, Kit Manual

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