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Yamaha R1 Series 2015, Service Manual


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TIGHTENING TORQUES

2-22

EAS30017

CHASSIS TIGHTENING TORQUES

Item

Thread 

size

Q’ty

Tightening torque

Remarks

Rear brake master cylinder lock nut

M8

1

16 Nm (1.6 m·kgf, 12 ft·lbf)

Front brake master cylinder bleed 

screw

M8

1

5 Nm (0.5 m·kgf, 3.6 ft·lbf)

Brake caliper bleed screw

M8

3

5 Nm (0.5 m·kgf, 3.6 ft·lbf)

Rear wheel axle nut

M24

1

190 Nm (19 m·kgf, 137 ft·lbf)

Chain puller adjusting bolt locknut

M8

2

16 Nm (1.6 m·kgf, 12 ft·lbf)

Shift rod locknut

M6

2

7 Nm (0.7 m·kgf, 5.1 ft·lbf)

IMU bolt

M4

4

2.0 Nm (0.20 m·kgf, 1.4 ft·lbf)

Passenger seat cover bolt (for YZF-

R1M)

M6

2

7 Nm (0.7 m·kgf, 5.1 ft·lbf)

Front side cowling bolt (for YZF-

R1M)

M6

2

9 Nm (0.9 m·kgf, 6.5 ft·lbf)

Front panel bolt (left)

M5

1

3.0 Nm (0.30 m·kgf, 2.2 ft·lbf)

Front panel bolt (right)

M5

1

3.5 Nm (0.35 m·kgf, 2.5 ft·lbf)

Side cover bolt

M5

3

3.8 Nm (0.38 m·kgf, 2.8 ft·lbf)

Windshield assembly bolt

M5

2

4.0 Nm (0.40 m·kgf, 2.9 ft·lbf)

Rearview mirror nut

M6

4

7 Nm (0.7 m·kgf, 5.1 ft·lbf)

Wheel sensor rotor bolt

M5

10

8 Nm (0.8 m·kgf, 5.8 ft·lbf)

Front brake disc bolt

M6

10

17 Nm (1.7 m·kgf, 12 ft·lbf)

Front wheel axle nut

M24

1

115 Nm (11.5 m·kgf, 83 ft·lbf)

Front wheel sensor bolt

M6

1

7 Nm (0.7 m·kgf, 5.1 ft·lbf)

Front wheel sensor protector bolt (for 

YZF-R1M)

M6

2

7 Nm (0.7 m·kgf, 5.1 ft·lbf)

Front brake caliper bolt

M10

4

35 Nm (3.5 m·kgf, 25 ft·lbf)

Front brake hose holder bolt

M6

2

6 Nm (0.6 m·kgf, 4.3 ft·lbf)

Front wheel axle pinch bolt

M8

4

21 Nm (2.1 m·kgf, 15 ft·lbf)

See TIP.

Rear wheel sprocket nut

M10

5

100 Nm (10 m·kgf, 72 ft·lbf)

Wheel bearing ring nut

M64

1

80 Nm (8.0 m·kgf, 58 ft·lbf)

Left thread

Rear brake disc bolt

M8

5

30 Nm (3.0 m·kgf, 22 ft·lbf)

Rear brake caliper bolt (front)

M12

1

27 Nm (2.7 m·kgf, 20 ft·lbf)

Rear brake caliper bolt (rear)

M8

1

12 Nm (1.2 m·kgf, 8.7 ft·lbf)

Rear wheel sensor protector bolt

M6

1

7 Nm (0.7 m·kgf, 5.1 ft·lbf)

Rear wheel sensor bolt

M6

1

7 Nm (0.7 m·kgf, 5.1 ft·lbf)

Front brake master cylinder holder 

bolt

M6

2

16 Nm (1.6 m·kgf, 12 ft·lbf)

Front brake hose union bolt

M10

5

32 Nm (3.2 m·kgf, 23 ft·lbf)

LT

LT

LT

LT

LS

LS

LT

Summary of Contents for R1 Series 2015

Page 1: ...2015 SERVICE MANUAL YZF R1 YZF R1F YZF R1M YZF R1MF 2CR 28197 E0...

Page 2: ......

Page 3: ...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...

Page 4: ...ificant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will appear in future editions of this manual where applicable TIP Designs and specifications are...

Page 5: ...o remove Q ty Remarks Front side cowling right Refer to GENERAL CHASSIS 2 on page 4 7 Engine oil Drain Refer to CHANGING THE ENGINE OIL on page 3 30 t c e n n o c s i D 1 e l b a c h c t u l C 1 1 r e...

Page 6: ...viceable with engine mounted Gear oil Filling fluid Molybdenum disulfide oil Lubricant Brake fluid Special tool Wheel bearing grease Tightening torque Lithium soap based grease Wear limit clearance Mo...

Page 7: ...GENERAL INFORMATION 1 SPECIFICATIONS 2 PERIODIC CHECKS AND ADJUSTMENTS 3 CHASSIS 4 ENGINE 5 COOLING SYSTEM 6 FUEL SYSTEM 7 ELECTRICAL SYSTEM 8 TROUBLESHOOTING 9 EAS10003 TABLE OF CONTENTS...

Page 8: ......

Page 9: ...E ABS 1 17 ABS COMPONENT FUNCTIONS 1 22 UBS AND ABS OPERATION 1 26 ABS WARNING LIGHT AND OPERATION 1 30 ABS AND UBS FUNCTION 1 31 GLOSSARY 1 32 DISPLAY 1 32 MENU SCREEN 1 36 IMPORTANT INFORMATION 1 48...

Page 10: ...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 se...

Page 11: ...ase it becomes necessary to control the air fuel ratio in a more precise and finely tuned manner To accom modate this need this model has adopted an electronically controlled fuel injection FI system...

Page 12: ...length of time the fuel injector is energized injection duration the lesser the volume of fuel that is supplied The injection duration and the injection timing are controlled by the ECU Signals that a...

Page 13: ...ator position sensor 8 Rear wheel sensor 9 Intake air temperature sensor 10 IMU Inertial Measurement Unit 11 O2 sensor 12 Catalytic converter 13 Coolant temperature sensor 14 Crankshaft position senso...

Page 14: ...ctivates the intake air funnel with the electronic control motor drive to control the intake pipe length in order to gain the high power output in all revolution ranges from low speeds to high speeds...

Page 15: ...CC I offers higher levels of power across the RPM range Electronically controlled intake length The YCC I system consists of four lightweight plastic resin funnels and each of these is divided into an...

Page 16: ...ttle 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 temperatu...

Page 17: ...r is shifted and is designed to add analog elements with a natural visual appearance even though it is a fully digital display In addition the tachometer bar display is designed to change color with t...

Page 18: ...machine attitude provided by the IMU is sent to the engine control unit ECU via CAN Controller Area Network transmission to enable real time calculations that are then reflected to provide optimum en...

Page 19: ...supports the TCS to contribute to smoother ride characteristics LIFt control system LIF to inhibit time loss due to front wheel lift and the like A LIFt control system LIF that smoothens machine motio...

Page 20: ...ment In addition two of the running modes in the Automatic mode have fine adjustment functions for the damping force to meet the needs of a wide range of running conditions To further increase the lat...

Page 21: ...us forms of machine information and simplifies the setting process in order to heighten the instrument panel s function as a rider machine interface Comprised of the CCU and a GPS antenna running data...

Page 22: ...er the UBS will not operate However if the brake pedal is operated while the UBS is operating the UBS will continue to operate until the brake pedal input exceeds the rear brake force generated by the...

Page 23: ...ke lever and brake pedal both operated a b a Input b No automatic pressurization a c b b a d A Brake lever is operated before brake pedal B Brake pedal is operated before brake lever a First input b S...

Page 24: ...0 The UBS does not operate before the vehicle starts off If the vehicle is stopped by operating the brake lever only the brake force due to the operation of the UBS will be maintained while the brake...

Page 25: ...starts and remains constant until the brake input stops When the brakes are operated continuously to slow the vehicle the coeffi cient UBS brake force does not decrease together with the vehicle speed...

Page 26: ...he appropriate pressure when the wheels have a tendency to lock or accord ing to the operation input hydraulic pressure from the brake lever or brake pedal 2 If the wheels have a tendency to lock duri...

Page 27: ...ng to reduce the wheel speed Wheel lock A condition that occurs when the rotation of one or both of the wheels has stopped but the vehicle continues to travel Side force The force on the tires which s...

Page 28: ...ties even on slippery road surfaces or less slippery road surfac es See figure B Wheel slip and hydraulic control The ABS ECU calculates the wheel speed of each wheel according to the rotation signal...

Page 29: ...eways WARNING EWA16510 The braking of the vehicle even in the worst case is principally executed when the vehicle is advancing straight ahead During a turn sudden braking is liable to cause a loss of...

Page 30: ...s Also there may be little or no additional rear brake force provided by the UBS If the UBS does not operate the front and rear brakes will oper ate independently according to the rider input and the...

Page 31: ...h is proportional to the magnetic flux density is converted into a wave in the hall IC so that it can be output The ABS ECU calculates the wheel rotation speed by detecting the pulse frequency 1 2 10...

Page 32: ...goes off when the vehicle is ridden at a speed of approximately 5 km h 3 mph NOTICE ECA22600 If the rear wheel is raced with the vehicle on a suitable stand the ABS warning light may come on If this...

Page 33: ...s continuously variable the solenoid valve moves smoothly and the hydraulic pressure is adjusted linear ly 1 Inlet solenoid valve This valve is open during normal braking and UBS operation The valve o...

Page 34: ...oting TIP Some types of malfunctions are not recorded in the memory of the ABS ECU e g a blown ABS so lenoid fuse 5 4 7 8 2 3 1 11 10 9 12 13 14 16 23 19 21 22 20 26 24 27 28 29 30 31 17 18 15 25 6 1...

Page 35: ...aulic pump check valve is closed The front brake master cylinder directly pressurizes the front brake calipers during normal braking When the brake le ver is released the brake fluid in the front brak...

Page 36: ...amber is pumped back to the brake master cylinder by the hydraulic pump linked to the ABS motor Pressurizing phase The outlet solenoid valve is closed by the pressurization signal transmitted from the...

Page 37: ...me the ABS is not activat ed the inlet solenoid valve is open and the outlet solenoid valve is closed because a control signal has not been transmitted from the ABS ECU The shuttle solenoid valve open...

Page 38: ...this time the hy draulic pressure is detected using the rear brake master cylinder pressure sensor and rear brake caliper pressure sensor and the separation solenoid valve and shuttle solenoid valve o...

Page 39: ...s on after riding conven tional braking performance of the vehicle is maintained 13 12 12 6 7 5 16 15 17 18 11 11 10 9 9 a 8 14 14 d b c e f 1 3 4 2 1 Front brake master cylinder 2 Brake lever 3 Rear...

Page 40: ...he cornering performance Depending on the road conditions the braking distance may be longer compared to that of vehicles not equipped with ABS Therefore ride at a safe speed and keep a safe distance...

Page 41: ...temperature warning icon Error mode Err TIP This model uses a thin film transistor liquid crys tal display TFT LCD for good contrast and readability in various lighting conditions Howev er due to the...

Page 42: ...pears 2 Short push the wheel switch and the item will flash for five seconds For STREET MODE if both items are resettable items the top item will flash first Scroll down to select the bot tom item 3 W...

Page 43: ...ting on page 1 37 and ERS YZF R1M on page 1 39 to change the registered ERS mode or adjust ERS setting levels TIP The ERS indicator will flash should the SCU need to be reset but this does not indicat...

Page 44: ...rate the engine if it is overheating Error mode When an error is detected the top portion of the main screen will switch to error mode The fol lowing error related warning icons and error codes will t...

Page 45: ...wheel switch briefly press the wheel switch inward to confirm the selec tion Triangle mark certain setting screens have an upward pointing triangle mark item Select the triangle mark to exit that scre...

Page 46: ...se and use PWR 4 for rainy days or whenever less engine power is desirable TCS This model uses a variable traction control sys tem For each setting level the further the vehi cle is leaned over the gr...

Page 47: ...e used when making upshifts TIP Turning the QSS on or off does not affect any other systems nor is QSS affected by the set tings of any other system LIF LIF can be set to 1 2 3 or OFF Setting level 3...

Page 48: ...nge to the front and rear suspension setting screen and the ERS mode selection box SETTING is highlight ed Short push the wheel switch to enter the box and select the ERS mode A 1 A 2 M 1 M 2 M 3 that...

Page 49: ...n memory If more than 40 laps are recorded the oldest laps starting from lap 1 will be overwritten This module has two options Display allows you to view the lap time record Reset allows you to delete...

Page 50: ...changes use the OIL item and for two other items of your choice use INTERVAL 1 and INTERVAL 2 To reset a maintenance item 1 From the MENU screen select Mainte nance 2 Select the item you want to rese...

Page 51: ...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...

Page 52: ...eel switch to adjust the r min at which the shift timing indicator will go off IND Stop opera tional range is 8500 15000 r min TIP The blue area on the tachometer indicates the currently set operation...

Page 53: ...depending on wallpa per settings When turned on the mid and mid to high r min zones can be set to come on in green and then orange colors 1 Select Tach IND Setting 2 Select IND Mode 3 Select ON to tu...

Page 54: ...IND Setting This module allows you to turn the revolution peak hold indicator on or off 1 Select Peak Rev IND Setting 2 Select IND Mode and then select ON to turn on the indicator or OFF to turn off t...

Page 55: ...re TRIP 1 tripmeter 1 TRIP 2 tripmeter 2 ODO odometer FUEL CON the amount of fuel consumed FUEL AVG average fuel consumption CRNT FUEL current fuel consumption 6 Select STREET MODE 1 2 or TRACK MODE t...

Page 56: ...e hour by rotating and then short push the wheel switch 4 The minutes figure will become highlighted 5 Set the minutes figure by rotating and then short push the wheel switch 6 Short push the wheel sw...

Page 57: ...ect installation of all 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...

Page 58: ...Oil bearings liberally when installing if appropriate NOTICE ECA13300 Do not spin the bearing with compressed air because this will damage the bearing surfac es EAS30011 CIRCLIPS Before reassembly che...

Page 59: ...ner push its pin so that it protrudes from the fastener head then insert the fastener into the part to be secured and push the pin a in with a screwdriver Make sure that the pin is flush with the fast...

Page 60: ...ld be gener ated which is extremely dangerous TIP If a battery lead is difficult to disconnect due to rust on the battery terminal remove the rust us ing hot water NOTICE ECA16760 Be sure to connect t...

Page 61: ...before turning the main switch back to ON NOTICE ECA22611 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...

Page 62: ...cks 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 moistu...

Page 63: ...upler or connector to gether until they are connected securely Make sure all connections are tight 4 Check Continuity with the pocket tester TIP If there is no continuity clean the terminals When chec...

Page 64: ...own were obtained at the standard measuring temperature of 20 qC 68 qF If the measuring temperature is not 20 qC 68 qF the specified measuring conditions will be shown Intake air temperature sensor re...

Page 65: ...rder refer to the list provided below to avoid any mistakes TIP For U S A and Canada use part number starting with YM YU or ACC For others use part number starting with 90890 Tool name Tool No Illustr...

Page 66: ...890 01382 Crankshaft protector YM 01382 5 36 Steering nut wrench 90890 01403 Exhaust flange nut wrench YU A9472 3 21 4 102 Flywheel puller 90890 01404 Flywheel puller YM 01404 5 36 Oil filter wrench 9...

Page 67: ...8703 4 85 4 87 Fork spring compressor 90890 01441 Fork spring compressor YM 01441 4 81 4 87 Fork seal driver 90890 01442 Adjustable fork seal driver 36 46 mm YM 01442 4 85 4 95 4 96 Pivot shaft wrench...

Page 68: ...l 90890 01550 Drive chain cut rivet tool YM 01550 4 117 4 119 Wheel bearing ring nut tool 90890 01574 YM 01574 4 38 4 39 Front fork cap bolt wrench 42mm 90890 01575 YM 01575 4 92 4 93 4 98 Front fork...

Page 69: ...r 90890 03112 Analog pocket tester YU 03112 C 1 54 8 179 8 180 8 184 8 185 8 186 8 187 8 188 8 190 8 191 8 192 8 194 8 195 8 196 Oil pressure gauge set 90890 03120 3 31 Pressure gauge 90890 03153 Pres...

Page 70: ...st harness S pressure sensor 3P YU 03207 8 193 8 194 Test harness speed sensor 3P 90890 03208 Test harness speed sensor 3P YU 03208 8 194 Fuel injector pressure adapter 90890 03210 Fuel injector press...

Page 71: ...04098 Valve guide installer 5 0 mm YM 04098 5 30 Valve guide reamer 5 90890 04099 Valve guide reamer 5 0 mm YM 04099 5 30 Valve guide remover 4 5 90890 04116 Valve guide remover 4 5 mm YM 04116 5 30...

Page 72: ...0 04173 YM 04173 5 80 Piston pin clip installer tool 90890 04174 YM 04174 5 81 Piston pin clip rotation tool 90890 04175 YM 04175 5 72 Oil pressure gauge joint 18 mm 90890 04176 YU 04176 3 31 Ignition...

Page 73: ...SPECIAL TOOLS 1 64 Yamaha bond No 1215 90890 85505 Three bond No 1215 5 37 5 67 Tool name Tool No Illustration Reference pages...

Page 74: ...SPECIAL TOOLS 1 65...

Page 75: ...TENING 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 LU...

Page 76: ...P 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 Over...

Page 77: ...Imp gal Engine oil Recommended brand YAMALUBE Type Full synthetic SAE 10W 40 or 15W 50 Recommended engine oil grade API service SG type or higher JASO standard MA Lubrication system Wet sump Engine o...

Page 78: ...haft journal diameter 25 459 25 472 mm 1 0023 1 0028 in Camshaft journal to camshaft cap clearance 0 028 0 062 mm 0 0011 0 0024 in Camshaft lobe dimensions Lobe height Intake 35 210 35 310 mm 1 3862 1...

Page 79: ...Limit 38 64 mm 1 52 in Free length exhaust 42 37 mm 1 67 in Limit 40 25 mm 1 58 in Installed length intake 35 40 mm 1 39 in Installed length exhaust 36 60 mm 1 44 in Installed compression spring forc...

Page 80: ...Black 3 Brown 4 Green 5 Yellow 6 Pink 7 Red Balancer Balancer shaft runout limit 0 030 mm 0 0012 in Balancer shaft journal to balancer shaft bear ing clearance 0 028 0 046 mm 0 0011 0 0018 in Bearing...

Page 81: ...Electrical Maximum consumption amperage 5 2 A Fuel injector Model quantity 297500 0640 4 Pri 297500 1640 4 2nd Resistance 12 0 20 qC 68 qF Throttle body Type quantity 45EIDW 1 ID mark 2CR1 00 Throttl...

Page 82: ...e Tubeless Size 120 70 ZR17M C 58W Manufacturer model YZF R1 BRIDGESTONE BATTLAX RACING STREET RS10F G or PIRELLI DIABLO SUPERCORSA SP YZF R1M BRIDGESTONE BATTLAX RACING STREET RS10F G Wear limit fron...

Page 83: ...Single disc brake Operation Right foot operation Rear disc brake Disc outside diameter u thickness 220 0 u 5 0 mm 8 66 u 0 20 in Brake disc thickness limit 4 5 mm 0 18 in Brake disc runout limit as me...

Page 84: ...um YZF R1 0 click s out YZF R1M ERS With the adjusting bolt fully turned in Compression damping adjusting positions Minimum YZF R1 23 click s out YZF R1M ERS Standard YZF R1 17 click s out YZF R1M ERS...

Page 85: ...st compression damping Minimum YZF R1 5 5 turn s out Standard YZF R1 3 turn s out Maximum YZF R1 0 turn s out With the adjusting bolt fully turned in Compression damping setting for slow compression d...

Page 86: ...BEL FRA TCI Pickup coil resistance 189 231 Gy B Ignition coil Minimum ignition spark gap 6 0 mm 0 24 in Primary coil resistance 0 85 1 15 Secondary coil resistance 8 50 11 50 k AC magneto Standard ou...

Page 87: ...ane Quantity 1 Maximum amperage 3 0 A Coil resistance 1 07 1 11 Solenoid Steering damper solenoid resistance 49 82 56 18 Intake solenoid resistance 42 00 48 00 Fuel injection sensor Crankshaft positio...

Page 88: ...5 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 Spare fuse...

Page 89: ...To avoid warpage tight en multi fastener assemblies in a crisscross pat tern and progressive stages until the specified tightening torque is reached Unless otherwise specified tightening torque specif...

Page 90: ...side M6 1 4 3 Nm 0 43 m kgf 3 1 ft lbf Throttle cable locknut throttle body side M6 2 4 5 Nm 0 45 m kgf 3 3 ft lbf Water pump drain bolt M6 1 10 Nm 1 0 m kgf 7 2 ft lbf Water pump air bleed bolt M6 1...

Page 91: ...t M6 3 10 Nm 1 0 m kgf 7 2 ft lbf Thermostat housing cover nut M6 2 10 Nm 1 0 m kgf 7 2 ft lbf Fuel pump bolt M5 4 4 0 Nm 0 40 m kgf 2 9 ft lbf Intake funnel assembly bolt M6 6 8 Nm 0 8 m kgf 5 8 ft l...

Page 92: ...t lbf Oil pan bolt M6 12 See TIP Baffle plate bolt M6 2 10 Nm 1 0 m kgf 7 2 ft lbf Clutch cover bolt M6 10 See TIP Clutch cover damper plate bolt M6 4 10 Nm 1 0 m kgf 7 2 ft lbf Crankcase breather cov...

Page 93: ...ater pump inlet pipe bolt M6 1 10 Nm 1 0 m kgf 7 2 ft lbf Water pump outlet pipe M6 4 10 Nm 1 0 m kgf 7 2 ft lbf Oil cooler stay bolt M6 3 10 Nm 1 0 m kgf 7 2 ft lbf Water pump housing cover bolt M6 2...

Page 94: ...wing the tightening order 3 Tighten the bolts to 45 Nm 4 5 m kgf 33 ft lbf with a torque wrench following the tightening order 4 Perform the following procedure to all the bolts one by one in the tigh...

Page 95: ...angle 90q TIP Clutch 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 th...

Page 96: ...lbf in the proper tight ening sequence 3 Tighten the crankcase bolts 1 10 further to reach the specified angle 75q in the proper tightening sequence 4 Tighten the crankcase bolts 11 40 11 20 24 Nm 2 4...

Page 97: ...or nut M6 4 7 Nm 0 7 m kgf 5 1 ft lbf Wheel sensor rotor bolt M5 10 8 Nm 0 8 m kgf 5 8 ft lbf Front brake disc bolt M6 10 17 Nm 1 7 m kgf 12 ft lbf Front wheel axle nut M24 1 115 Nm 11 5 m kgf 83 ft l...

Page 98: ...F R1 M10 2 15 Nm 1 5 m kgf 11 ft lbf Lower bracket pinch bolt M8 4 23 Nm 2 3 m kgf 17 ft lbf See TIP Front fork cap bolt for YZF R1 M46 2 23 Nm 2 3 m kgf 17 ft lbf Front fork damper rod assembly for Y...

Page 99: ...bolt M5 2 5 Nm 0 5 m kgf 3 6 ft lbf Bottom cowling bolt for YZF R1 M6 2 9 Nm 0 9 m kgf 6 5 ft lbf Front side cowling bracket bolt M6 4 9 Nm 0 9 m kgf 6 5 ft lbf ECU cover bolt M5 1 3 8 Nm 0 38 m kgf...

Page 100: ...fluid reservoir bracket bolt M6 1 7 Nm 0 7 m kgf 5 1 ft lbf Footrest plate bolt front M6 2 13 Nm 1 3 m kgf 9 4 ft lbf Footrest plate bolt rear M6 1 7 Nm 0 7 m kgf 5 1 ft lbf Brake hose joint bolt M6...

Page 101: ...the front fork If necessary manually push the front axle or lightly tap it with a soft hammer until its end is flush with the front fork However if the surface of the front axle end is not parallel t...

Page 102: ...ournals Balancer shaft journals Generator rotor bolt thread and washer Timing chain sprocket bolt Coolant pipe O ring Water or Oil pump rotors inner and outer Oil filter cartridge union bolt Plug oil...

Page 103: ...ings seal lip and ball race lip Tube guide throttle grip inner surface and throttle cables Brake lever pivot bolt and metal to metal moving parts Clutch lever pivot bolt metal to metal moving parts an...

Page 104: ...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 Rear brake caliper bolts Front brake disc a...

Page 105: ...LUBRICATION POINTS AND LUBRICANT TYPES 2 30...

Page 106: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 31 EAS20019 LUBRICATION SYSTEM CHART AND DIAGRAMS EAS30020 ENGINE OIL LUBRICATION CHART...

Page 107: ...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 Exhau...

Page 108: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 33 EAS30021 LUBRICATION DIAGRAMS Crankcase cylinder and cylinder head left side view...

Page 109: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 34 1 Intake camshaft 2 Oil nozzle 3 Oil delivery pipe 2 4 Oil filter cartridge 5 Crankshaft 6 Exhaust camshaft 7 Sub gallery...

Page 110: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 35 Crankcase and cylinder right side view...

Page 111: ...DIAGRAMS 2 36 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...

Page 112: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 37 Timing chain cover and oil pipe right side view...

Page 113: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 38 1 Timing chain cover 2 Oil pipe 3 3 Oil pipe 2 4 Crankshaft 5 Crankcase...

Page 114: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 39 Oil pump and oil cooler bottom view...

Page 115: ...l 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...

Page 116: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 41 Camshaft and balancer shaft top view...

Page 117: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 42 1 Cylinder head 2 Exhaust camshaft 3 Intake camshaft 4 Balancer shaft...

Page 118: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 43 Crankshaft rear view...

Page 119: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 44 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...

Page 120: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 45 Crankshaft and transmission top view...

Page 121: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 46 1 Oil pump 2 Main axle 3 Clutch housing 4 Drive axle 5 Oil delivery pipe 3...

Page 122: ...COOLING SYSTEM DIAGRAMS 2 47 EAS20020 COOLING SYSTEM DIAGRAMS...

Page 123: ...COOLING SYSTEM DIAGRAMS 2 48 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...

Page 124: ...COOLING SYSTEM DIAGRAMS 2 49...

Page 125: ...COOLING SYSTEM DIAGRAMS 2 50 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...

Page 126: ...CABLE ROUTING 2 51 EAS20021 CABLE ROUTING Handlebar front view...

Page 127: ...ad right has the corrugated tube installed at the base of the area where the sub wire harness branches out I Route the front fork stepping motor sub lead left to the front of the clutch cable J Route...

Page 128: ...CABLE ROUTING 2 53 Clutch cable right side view...

Page 129: ...sitioning tape and the radiator stay with the plastic locking tie B Fasten the coolant reservoir breather hose at the painted section and the clutch cable with the clamp C Cross the coolant reservoir...

Page 130: ...CABLE ROUTING 2 55 O2 sensor lead right side view...

Page 131: ...tch lead 4 EXUP cable A Push in the O2 sensor lead from the outside until it reaches the alignment surface of the clutch cover B Route the rear wheel sensor lead to the out side of the EXUP cables C R...

Page 132: ...CABLE ROUTING 2 57 Electrical components tray left side view...

Page 133: ...switch lead 1 pole from front of the rib D on the electrical compo nents tray to the inside D Rib on the electrical components tray E Connect the headlight control unit lead at the top to the headligh...

Page 134: ...CABLE ROUTING 2 59 ECU Engine Control Unit left side view...

Page 135: ...sten the straight portion of the thermostat assembly and stator coil assembly lead with the plastic locking tie Point the end of the plastic locking tie rearward and diagonally downward Do not cut off...

Page 136: ...CABLE ROUTING 2 61 Frame top view...

Page 137: ...he lead in the headlight assembly E Install the meter assembly coupler and cou pler cover securely to the meter assembly Make sure that the edges of the coupler cover are not rolled up F To front left...

Page 138: ...CABLE ROUTING 2 63 Frame top view for YZF R1M...

Page 139: ...of the plastic locking tie does not protrude above the intake sole noid vacuum hose E Connect the coupler of the sub wire harness front fork stepping motor to the coupler of the sub wire harness SCU...

Page 140: ...CABLE ROUTING 2 65 Frame top view...

Page 141: ...Fasten the intake solenoid vacuum hose with the plastic locking tie using the rear position of the wire harness clamp as a guide Make sure that the end of the plastic locking tie does not protrude ab...

Page 142: ...CABLE ROUTING 2 67 Frame top view...

Page 143: ...ar shock absorber assembly stepping motor lead to the fuel rail with the plastic locking tie Point the end of the plastic locking tie down ward Do not cut off the excess end of the plastic locking tie...

Page 144: ...CABLE ROUTING 2 69 Rear fender top view...

Page 145: ...light switch lead to the brake hose with the plastic locking tie Point the end of the plastic locking tie downward E Route the rear wheel sensor lead to the out side of the EXUP cable 1 and between t...

Page 146: ...CABLE ROUTING 2 71 Rear fender left side view...

Page 147: ...ead under the rear turn signal light coupler B Rear left turn signal light Connect the black couplers Rear right turn signal light Connect the white couplers The rear left turn signal light coupler an...

Page 148: ...CABLE ROUTING 2 73 Rear brake hose right side view...

Page 149: ...heel sensor lead at the back G Install the clamp at a position 0 10 mm 0 0 39 in from the top edge of the brake hose protector H Fasten the rear wheel sensor lead at under the white tape with the clam...

Page 150: ...CABLE ROUTING 2 75 Front brake hose left side view...

Page 151: ...r cylinder B Install the clamp with the opening facing for ward C Install the clamp to the top side of the rim on the brake hose D Route the front wheel sensor lead along the brake hose left without a...

Page 152: ...CABLE ROUTING 2 77 Front brake hose left side view...

Page 153: ...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 2 79 Hydraulic unit assembly top and left side view...

Page 155: ...5 Hydraulic unit brake pipe hydraulic unit to rear brake caliper 6 Hydraulic unit brake pipe rear brake master cylinder to hydraulic unit 7 Hydraulic unit 8 Rear frame 9 Battery box 10 Rear brake hose...

Page 156: ...CABLE ROUTING 2 81 Fuel tank top and left side view...

Page 157: ...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...

Page 158: ...CABLE ROUTING 2 83 Air filter case and throttle bodies top and left side view...

Page 159: ...amp 11 Fuel hose fuel pump to fuel rail A To one way valve Intake solenoid B When installing the crankcase breather hose may apply silicone fluid to the crankcase breather hose C Connector color Black...

Page 160: ...CABLE ROUTING 2 85 Air cut off valve right side view...

Page 161: ...hose with its white paint mark facing outward Make sure that the clamp is not installed on the flange of the hose fitting of the air filter case When installing the air induction system hose may appl...

Page 162: ...CABLE ROUTING 2 87 Air duct left and right side view...

Page 163: ...id vacuum hoses up the end of the intake solenoid C Insert the intake solenoid vacuum hose up to the end of the R section of the air intake duct valve pipe D Insert the surge tank hose up to the end o...

Page 164: ...CABLE ROUTING 2 89 Radiator left side view...

Page 165: ...on on the thermo stat assembly and oval shaped projections on the hose clamp Insert the radiator inlet hose until it contacts the projection on the thermostat assembly F Clamp installation details G 2...

Page 166: ...CABLE ROUTING 2 91 Radiator right side view...

Page 167: ...hose up to the center of the black paint mark on the water pump inlet pipe E Clamp installation details F 2 mm 0 08 in or more G Installed length 20 mm 0 79 in H Make sure that the clamp is not insta...

Page 168: ...CABLE ROUTING 2 93 Muffler top and left side view...

Page 169: ...CABLE ROUTING 2 94 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...

Page 170: ...CABLE ROUTING 2 95 CCU top and right side view for YZF R1M...

Page 171: ...Connect the CCU coupler sub wire harness to the CCU D Insert the Yamaha diagnostic tool coupler until it contacts the battery box E Align the end of the corrugate tube with the end of the clamp F Fast...

Page 172: ...CABLE ROUTING 2 97...

Page 173: ...G THE FRONT BRAKE PADS 3 15 ADJUSTING THE REAR DISC BRAKE 3 15 CHECKING THE REAR BRAKE PADS 3 15 CHECKING THE FRONT BRAKE HOSES 3 16 CHECKING THE REAR BRAKE HOSE 3 16 BLEEDING THE HYDRAULIC BRAKE SYST...

Page 174: ...EL 3 29 CHANGING THE ENGINE OIL 3 30 MEASURING THE ENGINE OIL PRESSURE 3 31 CHECKING THE COOLANT LEVEL 3 32 CHECKING THE COOLING SYSTEM 3 32 CHANGING THE COOLANT 3 33 ADJUSTING THE EXUP CABLES 3 35 CH...

Page 175: ...ODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM EAS30615 GENERAL MAINTENANCE AND LUBRICATION CHART NO ITEM CHECK OR MAINTENANCE JOB ODOMETER READING ANNUAL CHECK 1000 km 600 mi 10000km 6000 mi...

Page 176: ...th lithium soap based grease Every 20000 km 12000 mi 13 Steering damper Check operation and for oil leakage 14 Chassis fasteners Make sure that all nuts bolts and screws are properly tight ened 15 Bra...

Page 177: ...d Replace the brake hoses every four years and if cracked damaged partly blacked surface on the brake hose 25 Engine oil filter cartridge Replace 26 Cooling system Check coolant level and vehi cle for...

Page 178: ...S 1 on page 4 1 EAS31633 CHECKING THE FUEL LINE Secondary injector 1 Remove Rider seat Refer to GENERAL CHASSIS 1 on page 4 1 Fuel tank cover Refer to GENERAL CHASSIS 2 on page 4 7 Fuel tank Refer to...

Page 179: ...cover Refer to GENERAL CHASSIS 2 on page 4 7 Rider seat Refer to GENERAL CHASSIS 1 on page 4 1 EAS30622 ADJUSTING THE VALVE CLEARANCE The following procedure applies to all of the valves TIP Valve cle...

Page 180: ...gauge 1 TIP Measure the valve clearance between the cam lobe and rocker arm c TIP If the valve clearance is incorrect record the measured reading Measure the valve clearance in the following sequence...

Page 181: ...he valve clearance 4 with a thick ness gauge 5 Remove Camshaft TIP Refer to CAMSHAFTS on page 5 9 When removing the timing chain and cam shafts fasten the timing chain with a wire to re trieve it if i...

Page 182: ...nd the valve pad num ber Example 1 60 mm 0 063 in 0 03 mm 0 001 in 1 63 mm 0 064 in The valve pad number is A63 e Round off the valve pad number according to the following table and then select the su...

Page 183: ...inutes 2 Check Engine idling speed Out of specification o Go to next step 3 Check ISC Idle Speed Control learning value 00 or 01 o Check the intake system 02 o Clean the throttle bodies Refer to CHECK...

Page 184: ...bodies may not oper ate properly TIP 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 synchr...

Page 185: ...re the crankcase breather hose is routed correctly 3 Install Fuel tank Refer to FUEL TANK on page 7 1 Fuel tank cover Refer to GENERAL CHASSIS 2 on page 4 7 Rider seat Refer to GENERAL CHASSIS 1 on pa...

Page 186: ...TANK on page 7 1 2 Remove Air filter case cover 1 3 Check Air filter element 1 Air filter seal Damage o Replace TIP Replace the air filter element every 40000 km 24000 mi of operation The air filter...

Page 187: ...on the handlebar side of the cable use the adjusting nut on the engine side Engine side a Remove the right front side cowling Refer to GENERAL CHASSIS 2 on page 4 7 b Loosen the locknut 1 c Turn the a...

Page 188: ...ay result in a harmful chemical reaction leading to poor brake performance When refilling be careful that water does not enter the brake fluid reservoir Water will significantly lower the boiling poin...

Page 189: ...st Brake pedal position a Loosen the locknut 1 b Turn the adjusting bolt 2 in direction a or b until the specified brake pedal position is obtained WARNING EWA13070 After adjusting the brake pedal pos...

Page 190: ...ARNING EWA14000 Always bleed the brake system when the brake related parts are removed NOTICE ECA22640 Bleed the brake system in the following or der 1st step Front brake master cylinder 2nd step Fron...

Page 191: ...repeat steps e to i and then fill the brake fluid reservoir to the proper level with the specified brake fluid l Tighten the bleed screw to specification m Fill the brake fluid reservoir to the proper...

Page 192: ...d always be by the same manufacturer and of the same design No guarantee con cerning handling characteristics can be giv en if a tire combination other than one approved by Yamaha is used on this vehi...

Page 193: ...to SWINGARM on page 4 112 EAS30643 LUBRICATING THE SWINGARM PIVOT 1 Lubricate Oil seals Collars Refer to INSTALLING THE SWINGARM on page 4 114 EAS30644 ADJUSTING THE DRIVE CHAIN SLACK NOTICE ECA13550...

Page 194: ...RIVE CHAIN The drive chain consists of many interacting parts If the drive chain is not maintained proper ly it will wear out quickly Therefore the drive chain should be serviced especially when the v...

Page 195: ...ouple of times to check that it moves smoothly c Loosen the lower ring nut 6 completely then tighten it to specification WARNING EWA13140 Do not overtighten the lower ring nut d Check the steering hea...

Page 196: ...ment o Repair or replace EAS30651 LUBRICATING THE SIDESTAND Lubricate the pivoting point metal to metal mov ing parts and spring contact point of the sides tand EAS30652 CHECKING THE SIDESTAND SWITCH...

Page 197: ...xactly match the above specifications due to small dif ferences in production the actual number of clicks always represents the entire adjusting range To obtain a precise adjustment it would be advisa...

Page 198: ...applies to both of the front fork legs WARNING EWA13120 Securely support the vehicle so that there is no danger of it falling over Spring preload WARNING EWA17040 Always adjust both front fork legs ev...

Page 199: ...e preset for street use with street tires 1 Adjust Damping force a Turn the main switch to ON b Long push the wheel switch to enter the MENU screen c Select YRC Setting d Select the mark located to th...

Page 200: ...SSEMBLY on page 4 109 EAS30655 ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY for YZF R1 WARNING EWA13120 Securely support the vehicle so that there is no danger of it falling over Spring preload NOTICE E...

Page 201: ...ons listed due to small differences in production Compression damping for fast compres sion damping NOTICE ECA13590 Never go beyond the maximum or minimum adjustment positions 1 Adjust Compression dam...

Page 202: ...OAD OF THE REAR SHOCK ABSORBER ASSEMBLY for YZF R1M WARNING EWA13120 Securely support the vehicle so that there is no danger of it falling over Spring preload NOTICE ECA13590 Never go beyond the maxim...

Page 203: ...ine oil level The engine oil level should be between the minimum level mark a and maximum level mark b Below the minimum level mark o Add the recommended engine oil to the proper level NOTICE ECA13361...

Page 204: ...d perform the following procedure a Remove the left front side cowling Refer to GENERAL CHASSIS 2 on page 4 7 b Remove the oil filter cartridge 1 with an oil filter wrench 2 c Lubricate the O ring 3 o...

Page 205: ...gine oil pressure to increase Therefore be sure to measure the engine oil pressure after warming up the engine 3 Remove Front side cowling left 4 Remove Oil pressure switch joint bolt 1 Oil pressure s...

Page 206: ...tion 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...

Page 207: ...h could cause serious in jury When the engine has cooled open the radiator cap as follows Place a thick rag or a towel over the radiator cap and slowly turn the radiator cap counter clockwise toward t...

Page 208: ...s not available soft water may be used If coolant comes into contact with painted surfaces immediately wash them with wa ter Do not mix different types of antifreeze 10 Fill Coolant reservoir with the...

Page 209: ...ion a on the EXUP valve pulley contacts the stopper b fully open posi tion If the projection does not contact the stop per adjust the EXUP cable free play 3 Adjust EXUP cable free play a Turn the main...

Page 210: ...dure applies to all of the in ner and outer cables WARNING EWA13270 Damaged outer cable may cause the cable to corrode and interfere with its movement Re place damaged outer cable and inner cables as...

Page 211: ...throttle grip free play cannot be obtained on the throttle body side of the cable use the adjusting nut on the handlebar side Handlebar side a Slide back the rubber cover 1 b Loosen the locknut 2 c T...

Page 212: ...d turn the adjusting screw a Turn the adjusting screws 1 in direction b or c 2 Adjust Headlight beam horizontally TIP To adjust the headlight beam horizontally in sert a crosshead screwdriver into the...

Page 213: ...PERIODIC MAINTENANCE 3 39 1 1 c b c b...

Page 214: ...PERIODIC MAINTENANCE 3 40...

Page 215: ...IELD ASSEMBLY 4 21 CHECKING THE AIR INTAKE DUCT VALVE 4 22 CHECKING THE VACUUM LINE 4 22 INSTALLING THE AIR INTAKE DUCT VALVE 4 23 FRONT WHEEL 4 24 REMOVING THE FRONT WHEEL 4 27 DISASSEMBLING THE FRON...

Page 216: ...4 62 REMOVING THE REAR BRAKE MASTER CYLINDER 4 63 CHECKING THE REAR BRAKE MASTER CYLINDER 4 63 THE REAR BRAKE MASTER CYLINDER 4 64 INSTALLING THE REAR BRAKE MASTER CYLINDER 4 64 ABS Anti lock Brake Sy...

Page 217: ...MBLY 4 108 DISASSEMBLING THE REAR SHOCK ABSORBER ASSEMBLY 4 109 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY 4 109 CHECKING THE CONNECTING ARM AND RELAY ARM 4 109 ASSEMBLING THE REAR SHOCK ABSORBER ASSEM...

Page 218: ...der seat 1 2 Passenger seat 1 3 Battery cover 1 4 Negative battery lead 1 Disconnect 5 Positive battery lead 1 Disconnect 6 Battery 1 7 IMU coupler 1 8 IMU Inertial Measurement Unit 1 7 Nm 0 7 m kgf 5...

Page 219: ...r side cover left 1 5 Tail brake light bracket 1 6 Tail brake light coupler 1 Disconnect 7 Tail brake light 1 8 Rear turn signal light coupler 2 Disconnect 9 License plate light coupler 1 Disconnect 1...

Page 220: ...e mudguard assembly Order Job Parts to remove Q ty Remarks 1 Mudguard assembly cover 1 2 Clamp 1 3 Stay 2 4 Rear turn signal light 2 5 Cover 1 6 License plate light 1 7 Rear reflector 1 3 4 5 6 7 3 8...

Page 221: ...unit coupler 1 Disconnect 3 Cushion 1 4 GPS unit 1 5 CCU coupler sub wire harness 1 Disconnect 6 Band 1 7 CCU Communication Control Unit 1 8 CCU bracket 1 1 9 CCU bracket 2 1 10 Yamaha diagnostic tool...

Page 222: ...upler 2 to the IMU b Install the IMU 1 washers and IMU bolts and then tighten the bolts to specification TIP Apply a thin coat of silicone grease onto the washers where contacting the grommets EAS3167...

Page 223: ...aha Motor Network by inputting the CCU serial number as the password TIP 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 c...

Page 224: ...g the fuel tank covers Order Job Parts to remove Q ty Remarks 1 Fuel tank cover left 1 2 Fuel tank cover right 1 3 Fuel tank front cover 1 4 0 Nm 0 40 m kgf 2 9 ft lbf 0 4 Nm 0 04 m kgf 0 29 ft lbf 1...

Page 225: ...fastener screw 4 4 Front side cowling left 1 5 Front side cowling inner panel right 1 6 Quick fastener 1 7 Quick fastener screw 4 8 Front side cowling right 1 9 Bottom cowling 1 10 Headlight cover 1...

Page 226: ...7 1 Quick fastener screw 3 2 Front side cowling left 1 3 Quick fastener screw 3 4 Front side cowling right 1 5 Headlight cover 1 6 Front side cowling bracket left 2 7 Front side cowling bracket right...

Page 227: ...ove the front side cowling left Refer to GENERAL CHASSIS 2 on page 4 7 3 ECU cover 1 4 ECU coupler 2 Disconnect 5 ECU Engine Control Unit 1 6 Side cover bracket left 1 7 Front muffler protector left 1...

Page 228: ...ight 1 When removing the side cover bracket also remove the front side cowling right Refer to GENERAL CHASSIS 2 on page 4 7 5 Side cover right 1 6 Front muffler protector right 1 1 3 4 5 6 3 8 Nm 0 38...

Page 229: ...t left Refer to GENERAL CHASSIS 2 on page 4 7 1 Radiator fan motor coupler 2 Disconnect 2 Handlebar switch coupler left 2 Disconnect 3 Handlebar switch coupler right 3 Disconnect 4 Rectifier regulator...

Page 230: ...WLINGS for YZF R1M 1 Remove Front side cowling left 1 a Remove the quick fastener screws 2 quick fasteners 3 bolt 4 and the collar 5 b Remove the left front side cowling by pulling it forward 2 Remove...

Page 231: ...tall Front side cowling left 1 a Install the left front side cowling b Install the quick fastener screws 2 quick fasteners 3 collar 4 and the bolt 5 EAS31639 REMOVING THE FRONT PANELS 1 Remove Front p...

Page 232: ...over bolt 2 b Remove the side cover 1 by sliding it rear ward EAS31520 INSTALLING THE SIDE COVER left 1 Install Side cover left 1 a Install the side cover 1 TIP Insert projections a on the side cover...

Page 233: ...g 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 Connect ECU coupler 1 TIP Conn...

Page 234: ...eld Order Job Parts to remove Q ty Remarks Front panel Refer to GENERAL CHASSIS 2 on page 4 7 1 Turn signal light coupler 2 Disconnect 2 Rearview mirror 2 3 Front upper cowling 1 4 Windshield 1 1 2 3...

Page 235: ...g damper solenoid coupler 1 Disconnect 3 Steering damper solenoid lead clamp 1 4 Meter assembly coupler 1 Disconnect 5 Fuse box 1 1 6 Intake solenoid vacuum hose 1 Disconnect 7 Auxiliary light coupler...

Page 236: ...1 2 Headlight control unit coupler 1 Disconnect 3 Headlight control unit 1 4 Headlight 1 5 Auxiliary light left 1 6 Auxiliary light right 1 7 SCU cover 1 8 SCU Suspension Control Unit 1 9 Front cowlin...

Page 237: ...solenoid vacuum hose 1 3 Air intake duct 1 4 Air duct 1 5 Intake air temperature sensor 1 6 Surge tank 1 7 Surge tank hose 1 8 One way valve 1 9 Intake solenoid vacuum hose one way valve to intake so...

Page 238: ...3 d Remove the windshield assembly 4 TIP Remove projections a on the windshield as sembly from grommets b EAS31644 INSTALLING THE WINDSHIELD ASSEMBLY 1 Install Windshield assembly a Install the winds...

Page 239: ...e duct valve operates when vacuum pressure is applied to the valve using the vacuum pressure pump gauge set Faulty o Replace the air intake duct valve EAS31646 CHECKING THE VACUUM LINE 1 Check Hoses L...

Page 240: ...5 6 Check Surge tank Cracks damage o Replace EAS31647 INSTALLING THE AIR INTAKE DUCT VALVE 1 Install Air intake duct valve a Hook the end of the shaft a onto the plate 1 as shown b Align the tabs b on...

Page 241: ...ront brake caliper 2 6 Wheel axle pinch bolt 4 Loosen 7 Front wheel axle nut 1 8 Front wheel axle 1 9 Front wheel 1 10 Collar 2 11 Front brake disc 2 12 Plate 2 1 2 3 4 5 6 7 8 9 10 11 12 17 Nm 1 7 m...

Page 242: ...sor 1 6 Front brake caliper 2 7 Wheel axle pinch bolt 4 Loosen 8 Front wheel axle nut 1 9 Front wheel axle 1 10 Front wheel 1 11 Collar 2 12 Front brake disc 2 13 Plate 2 1 2 3 4 5 9 11 17 Nm 1 7 m kg...

Page 243: ...HEEL 4 26 Disassembling the front wheel Order Job Parts to remove Q ty Remarks 1 Front wheel sensor rotor 1 2 Oil seal 2 3 Wheel ring 1 4 Wheel bearing 2 5 Spacer 1 1 2 2 3 4 4 5 8 Nm 0 8 m kgf 5 8 ft...

Page 244: ...nsor from the sensor housing 3 Elevate Front wheel TIP Place the vehicle on a suitable stand so that the front wheel is elevated 4 Loosen Wheel axle pinch bolt 5 Remove Front wheel axle Front wheel EA...

Page 245: ...tor wipe it off immediately 1 Install Wheel bearings Oil seals a Install the new wheel bearing right side NOTICE ECA18110 Do not contact the wheel bearing inner race 1 or balls 2 Contact should be mad...

Page 246: ...ewdrivers etc away from the front wheel sensor or front wheel sensor rotor Do not drop or shock the wheel sensor or the wheel sensor rotor 1 Check Front wheel sensor 1 Cracks bends distortion o Replac...

Page 247: ...1 Remove Balancing weight s 2 Find Front wheel s heavy spot TIP Place the front wheel on a suitable balancing stand a Spin the front wheel b When the front wheel stops put an X1 mark at the bottom of...

Page 248: ...INSTALLING THE FRONT WHEEL DISC BRAKE 1 Install Plate Front brake discs NOTICE ECA19150 Replace the brake disc bolts with new ones TIP Tighten the brake disc bolts in stages and in a crisscross patte...

Page 249: ...M NOTICE ECA21020 Make sure there are no foreign materials in the front wheel sensor rotor and front wheel sensor Foreign materials cause damage to the front wheel sensor rotor and front wheel sensor...

Page 250: ...and the front wheel sensor 10 Install Front brake calipers Front brake hose holder WARNING EWA13500 Make sure the brake hose is routed properly Distance a between the front wheel sensor rotor and fro...

Page 251: ...nsor protector 1 2 Rear wheel sensor 1 3 Locknut 2 Loosen 4 Adjusting bolt 2 Loosen 5 Rear wheel axle nut 1 6 Washer 1 7 Rear wheel axle 1 8 Adjusting block left 1 9 Adjusting block right 1 10 Rear wh...

Page 252: ...1 4 Rear wheel sprocket 1 5 Collar 1 6 Collar 1 7 Oil seal 1 8 Bearing 1 9 Rear wheel drive hub 1 1 10 Rear wheel drive hub damper 5 11 Rear wheel drive hub 2 1 12 Gasket 5 13 Rear wheel 1 1 2 3 4 5 6...

Page 253: ...ssembling the rear wheel Order Job Parts to remove Q ty Remarks 1 Collar 1 2 Oil seal 1 3 Wheel bearing 1 4 Spacer 1 5 Oil seal 1 6 Wheel bearing ring nut 1 7 Wheel bearing 1 1 2 3 4 5 6 7 80 Nm 8 0 m...

Page 254: ...ear wheel sensor protector 2 Rear wheel sensor 3 NOTICE ECA21040 Do not depress the brake pedal when re moving the brake caliper Be sure not to contact the sensor electrode to any metal part when remo...

Page 255: ...n page 4 27 2 Check Tire Rear wheel Damage wear o Replace Refer to CHECKING THE TIRES on page 3 17 and CHECKING THE WHEELS on page 3 17 3 Measure Radial wheel runout Lateral wheel runout Refer to CHEC...

Page 256: ...ely 1 Install Wheel bearings Oil seal Refer to ASSEMBLING THE FRONT WHEEL on page 4 28 2 Install Wheel bearing ring nut TIP Apply locking agent LOCTITE onto the two symmetric places on the circumferen...

Page 257: ...r rotor 1 Check Rear wheel sensor Refer to MAINTENANCE OF THE FRONT WHEEL SENSOR AND SENSOR ROTOR on page 4 29 2 Check Rear wheel sensor rotor Refer to MAINTENANCE OF THE FRONT WHEEL SENSOR AND SENSOR...

Page 258: ...ction c faces to the front of the vehicle 5 Install Rear brake caliper Rear brake caliper bolts 6 Adjust Drive chain slack Refer to ADJUSTING THE DRIVE CHAIN SLACK on page 3 19 7 Tighten Rear wheel ax...

Page 259: ...e wrong in stallation direction rotor decentering LOC TITE on the mounting surface of the rotor deformation caused by an impact during ser vice and caught foreign materials If there is any defective p...

Page 260: ...f the front brake calipers 1 Brake pad clip 2 2 Brake pad pin 1 3 Brake pad spring 1 4 Brake pad 2 5 Reflector 1 For AUS 2CR6 2KS6 RUS 6 Front brake hose holder 1 7 Front brake caliper 1 8 Bleed screw...

Page 261: ...oir 1 6 Brake fluid reservoir hose 1 7 Brake lever 1 8 Front brake light switch lead connector 2 Disconnect 9 Brake hose union bolt 1 10 Brake hose gasket 2 11 Brake hose 1 12 Front brake master cylin...

Page 262: ...5 Disassembling the front brake master cylinder Order Job Parts to remove Q ty Remarks 1 Brake master cylinder kit 1 2 Bleed screw 1 3 Cap 1 4 Brake master cylinder body 1 1 1 2 3 4 5 Nm 0 5 m kgf 3 6...

Page 263: ...brake calipers Brake fluid Drain Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM ABS on page 3 16 1 Reflector 1 For AUS 2CR6 2KS6 RUS 2 Front brake hose holder 1 3 Brake hose union bolt 1 4 Brake hose ga...

Page 264: ...both of the front brake calipers 1 Brake pad clip 2 2 Brake pad pin 1 3 Brake pad spring 1 4 Brake pad 2 5 Brake caliper piston 4 6 Brake caliper piston dust seal 4 7 Brake caliper piston seal 4 8 Bl...

Page 265: ...move Front wheel Refer to FRONT WHEEL on page 4 24 2 Check Front brake disc Damage galling o Replace 3 Measure Brake disc runout Out of specification o Correct the brake disc runout or replace the bra...

Page 266: ...ble the brake caliper 1 Remove Brake pad clips 1 Brake pad pin 2 Brake pad spring 3 2 Remove Brake pads 1 3 Measure Brake pad wear limit a Out of specification o Replace the brake pads as a set 4 Rem...

Page 267: ...ke lever operation Soft or spongy feeling o Bleed the brake sys tem Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM ABS on page 3 16 EAS30171 REMOVING THE FRONT BRAKE CALIPERS The following procedure app...

Page 268: ...he brake caliper pistons Brake caliper cylinders 2 Scratches wear o Replace the brake caliper assembly Brake caliper body 3 Cracks damage o Replace the brake caliper assembly Brake fluid delivery pass...

Page 269: ...gnated brake fluid Other brake fluids may cause the rubber seals to deteriorate causing leakage and poor brake performance Refill with the same type of brake fluid that is already in the system Mixing...

Page 270: ...cylinder body Obstruction o Blow out with compressed air 2 Check Brake master cylinder kit Damage scratches wear o Replace 3 Check Brake fluid reservoir 1 Brake fluid reservoir diaphragm holder 2 Cra...

Page 271: ...iorate causing leakage and poor brake performance Refill with the same type of brake fluid that is already in the system Mixing brake fluids may result in a harmful chemical reaction leading to poor b...

Page 272: ...1 2 Brake pad retaining bolt 1 3 Rear brake caliper 1 4 Brake pad 2 5 Brake pad shim 2 6 Brake pad insulator 2 7 Brake pad spring 1 8 Bleed screw 1 12 Nm 1 2 m kgf 8 7 ft lbf 5 Nm 0 5 m kgf 3 6 ft Ib...

Page 273: ...fluid reservoir diaphragm 1 4 Brake fluid reservoir 1 5 Brake fluid reservoir bracket 1 6 Brake fluid reservoir hose 1 7 Brake hose union bolt 1 8 Brake hose gasket 2 9 Brake hose 1 10 Footrest plate...

Page 274: ...ty Remarks Brake fluid Drain Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM ABS on page 3 16 1 Brake hose union bolt 1 2 Brake hose gasket 2 3 Brake hose 1 4 Rear brake caliper 1 3 4 1 2 S 12 Nm 1 2 m k...

Page 275: ...1 3 Brake pad 2 4 Brake pad shim 2 5 Brake pad insulator 2 6 Brake pad spring 1 7 Brake caliper piston 1 8 Brake caliper piston dust seal 1 9 Brake caliper piston seal 1 10 Bleed screw 1 11 Caliper b...

Page 276: ...place 3 Measure Brake disc runout Out of specification o Correct the brake disc runout or replace the brake disc Refer to CHECKING THE FRONT BRAKE DISCS on page 4 48 4 Measure Brake disc thickness Mea...

Page 277: ...iper piston 3 Lubricate Rear brake caliper bolts NOTICE ECA14150 Do not allow grease to contact the brake pads Remove any excess grease 4 Install Rear brake caliper Brake pad retaining bolts Screw plu...

Page 278: ...caliper pis ton b Remove the brake caliper piston dust seal and brake caliper piston seal EAS30188 CHECKING THE REAR BRAKE CALIPER 1 Check Brake caliper piston 1 Rust scratches wear o Replace the bra...

Page 279: ...ets Brake hose 2 Brake hose union bolt 3 WARNING EWA13531 Proper brake hose routing is essential to in sure safe vehicle operation NOTICE ECA19080 When installing the brake hose onto the brake caliper...

Page 280: ...6 Check Brake fluid level Below the minimum level mark a o Add the specified brake fluid to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL on page 3 14 7 Check Brake pedal operation Soft or...

Page 281: ...formance Refill with the same type of brake fluid that is already in the system Mixing brake fluids may result in a harmful chemical reaction leading to poor brake performance When refilling be carefu...

Page 282: ...M ABS on page 3 16 1 Fuel tank bracket 1 2 Damper 1 3 ABS ECU coupler 1 Disconnect 4 Hydraulic unit brake pipe rear brake master cyl inder to hydraulic unit 1 5 Hydraulic unit brake pipe hydraulic uni...

Page 283: ...ake hose hydraulic unit to front brake cali pers 1 13 Brake hose rear brake master cylinder to hydraulic unit 1 14 Brake hose hydraulic unit to rear brake caliper 1 15 Brake hose joint 1 16 Rear brake...

Page 284: ...sor 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 b...

Page 285: ...emoved be sure to tighten them to the specified torque and bleed the brake system 1 Disconnect ABS ECU coupler 1 TIP While pushing the portion a of the ABS ECU coupler pull the lock lever up to releas...

Page 286: ...s when installing the hydraulic unit as sembly 2 Remove Rubber plugs or bolts M10 u 1 0 3 Install Hydraulic unit brake pipe 4 Tighten Hydraulic unit brake pipe flare nuts NOTICE ECA19820 If the brake...

Page 287: ...codes Refer to B 3 DE LETING THE FAULT CODES on page 8 150 11 Perform a trial run Refer to CHECKING THE ABS WARNING LIGHT on page 4 73 EAS30201 HYDRAULIC UNIT OPERATION TEST The reaction force pulsat...

Page 288: ...draulic unit have not been met Off The brake lever and brake pedal are not being operated 9 Check Hydraulic unit operation Click Action a single pulse will be generat ed in the brake lever 1 brake ped...

Page 289: ...attery voltage is lower than 12 8 V charge the battery and then perform ABS reaction force confirmation 5 Removing the protective cap 1 and then connect the Yamaha diagnostic tool to the Yamaha diagno...

Page 290: ...d and re leased respectively NOTICE ECA17371 Check that the pulse is felt in the brake le ver brake pedal and again in the brake le ver in this order If the pulse is felt in the brake pedal before it...

Page 291: ...nect 4 Handlebar switch coupler left 2 Disconnect 5 Handlebar switch left 1 6 Clutch cable 1 Disconnect 7 Clutch lever holder 1 8 Grip end right 1 9 Throttle cable housing 2 10 Throttle cable 2 Discon...

Page 292: ...connect 18 Immobilizer coupler 1 Disconnect 19 Upper bracket 1 20 Handlebar left 1 21 Handlebar right 1 13 14 15 16 17 18 19 20 21 LT 7 Nm 0 7 m kgf 5 1 ft Ibf 26 Nm 2 6 m kgf 19 ft lbf 32 Nm 3 2 m kg...

Page 293: ...r as this may dangerously weaken it EAS30205 INSTALLING THE HANDLEBARS 1 Stand the vehicle on a level surface WARNING EWA13120 Securely support the vehicle so that there is no danger of it falling ove...

Page 294: ...h the hole b in the handlebar 8 Install Handlebar grip 1 Grip end 2 a Apply a thin coat of rubber adhesive onto the end of the left handlebar b Side the handlebar grip over the end of the left handleb...

Page 295: ...ay Refer to ADJUSTING THE CLUTCH LEVER FREE PLAY on page 3 13 10 Adjust Clutch lever free play Refer to CHECKING THE THROTTLE GRIP on page 3 36 Throttle grip free play 3 0 5 0 mm 0 12 0 20 in Clutch l...

Page 296: ...t fork legs Front wheel Refer to FRONT WHEEL on page 4 24 1 Front fender 1 2 Upper bracket pinch bolt 1 Loosen 3 Handlebar pinch bolt 1 Loosen 4 Handlebar bolt 1 Loosen 5 Cap bolt 1 Loosen 6 Lower bra...

Page 297: ...both of the front fork legs 1 Cap bolt 1 2 O ring 1 3 Guide 1 4 Spacer 1 5 Fork spring 1 6 Locknut 1 7 Damper adjusting rod 1 1 8 Damper adjusting rod 2 1 9 Dust seal 1 10 Oil seal clip 1 11 Outer tub...

Page 298: ...WARNING EWA13640 Before loosening the upper and lower brack et pinch bolts support the front fork leg 4 Remove Front fork leg EAS30207 DISASSEMBLING THE FRONT FORK LEGS for YZF R1 The following proced...

Page 299: ...al 1 Oil seal clip 2 with a flat head screwdriver NOTICE ECA19100 Do not scratch the outer tube 5 Remove Outer tube a Hold the front fork leg horizontally b Securely clamp the brake caliper bracket in...

Page 300: ...r 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 4 Check Cap bolt 1 Cap bolt collar projection 2 Crack...

Page 301: ...seal clip 2 Oil seal 3 Washer 4 Outer tube bushing 5 Inner tube bushing 6 NOTICE ECA19170 Make sure the numbered side of the oil seal faces bottom side TIP Before installing the oil seal lubricate its...

Page 302: ...10 2 onto the damper rod 3 11 Fill Front fork leg with the specified amount of the recom mended fork oil Fork seal driver 90890 01442 Adjustable fork seal driver 36 46 mm YM 01442 Fork seal driver 908...

Page 303: ...Be sure to bleed the front fork leg of any residual air 14 Measure Front fork leg oil level a from the top of the outer tube with the outer tube fully compressed and without the fork spring Out of spe...

Page 304: ...the outer tube TIP Temporarily tighten the cap bolt When to tighten the cap bolt to the specified torque is after installing the front fork leg to the vehicle and tightening the lower bracket pinch bo...

Page 305: ...k Cable routing TIP Make sure the brake hose throttle cables clutch cable and handlebar switch leads are routed properly Refer to CABLE ROUTING on page 2 51 5 Install Plastic locking tie 1 TIP Fasten...

Page 306: ...FRONT FORK for YZF R1 4 89 Refer to ADJUSTING THE FRONT FORK LEGS for YZF R1 on page 3 23...

Page 307: ...4 24 1 Front fender 1 2 Upper bracket pinch bolt 1 Loosen 3 Handlebar pinch bolt 1 Loosen 4 Handlebar bolt 1 Loosen 5 Front fork stepping motor coupler 1 Disconnect 6 Cap bolt with front fork steppin...

Page 308: ...th of the front fork legs 1 Cap bolt with front fork stepping motor 1 2 O ring 1 3 Locknut 1 4 Upper spring seat 1 5 Fork spring 1 6 Spacer 1 7 Outer tube 1 8 Dust seal 1 9 Oil seal clip 1 10 Oil seal...

Page 309: ...nch bolt 1 Upper bracket pinch bolt 2 Handlebar bolt 3 Cap bolt 4 Lower bracket pinch bolts 5 WARNING EWA13640 Before loosening the upper and lower brack et pinch bolts support the front fork leg TIP...

Page 310: ...wdriver Oil seal Washer 6 Remove Damper rod assembly TIP Remove the damper rod assembly with the damper rod holder 1 EAS31650 CHECKING THE FRONT FORK LEGS for YZF R1M The following procedure applies t...

Page 311: ...plies to both of the front fork legs WARNING EWA17090 Note that the amount of the fork oil is differ ent in the left and right front fork legs Make sure to fill each of the left and right front fork l...

Page 312: ...ube with fork oil Before installing the oil seal cover the top of the front fork leg with a plastic bag to protect the oil seal during installation 5 Install Outer tube to the inner tube 6 Install Was...

Page 313: ...s to distribute the fork oil TIP Be sure to stroke the damper rod slowly be cause the fork oil may spurt out 12 Before measuring the fork oil level wait ten minutes until the oil has settled and the a...

Page 314: ...ys use a new cap bolt O ring g Hold the spring preload adjusting bolt 3 and tighten the locknut 2 to specification 15 Install Cap bolt to the outer tube TIP Temporarily tighten the cap bolt When to ti...

Page 315: ...andlebar bolt 3 Handlebar pinch bolt 4 Upper bracket pinch bolt 5 TIP When installing the front fork legs make sure that the front fork stepping motor couplers are positioned at the angles shown in th...

Page 316: ...1 TIP Fasten the front brake hose to the right front fork leg with the plastic locking tie 6 Adjust Spring preload Rebound damping Compression damping Refer to ADJUSTING THE PRELOAD OF THE FRONT FORK...

Page 317: ...efer to FRONT FORK for YZF R1 on page 4 79 or refer to FRONT FORK for YZF R1M on page 4 90 Upper bracket Handlebars Refer to HANDLEBARS on page 4 74 1 Horn connector 2 Disconnect 2 Horn 1 3 Front brak...

Page 318: ...s to remove Q ty Remarks 10 Rubber washer 1 11 Lower ring nut 1 12 Lower bracket 1 13 Bearing cover 1 14 Lower bearing dust seal 1 15 Upper bearing 1 16 Lower bearing 1 LT 10 11 12 13 14 15 16 11 Nm 1...

Page 319: ...sh Bearing Bearing race 2 Check Bearing 1 Bearing race 2 Damage pitting o Replace the bearings and bearing races as a set 3 Replace Bearing Bearing race a Remove the bearing races from the steering he...

Page 320: ...ut Refer to HANDLEBARS on page 4 74 TIP Temporarily tighten the steering stem nut 4 Install Front fork legs Refer to FRONT FORK for YZF R1 on page 4 79 or refer to FRONT FORK for YZF R1M on page 4 90...

Page 321: ...1 Rear brake caliper Refer to REAR BRAKE on page 4 55 Rear wheel Refer to REAR WHEEL on page 4 34 1 Connecting arm upper nut Washer Bolt 1 1 1 2 Rear shock absorber assembly lower nut Bolt 1 1 3 Conn...

Page 322: ...ts to remove Q ty Remarks 10 Oil seal Bearing 2 1 11 Collar Oil seal Bearing 1 2 2 12 Collar Oil seal Bearing 1 2 1 13 Collar Dust seal Circlip Bushing 2 2 1 1 14 Collar Oil seal Bearing 1 2 2 12 11 1...

Page 323: ...r to REAR WHEEL on page 4 34 1 Rear shock absorber assembly stepping motor coupler 2 Disconnect 2 Connecting arm upper nut Washer Bolt 1 1 1 3 Rear shock absorber assembly lower nut Bolt 1 1 4 Connect...

Page 324: ...1M Order Job Parts to remove Q ty Remarks 12 Collar Oil seal Bearing 1 2 2 13 Collar Oil seal Bearing 1 2 1 14 Collar Dust seal Circlip Bushing 2 2 2 1 15 Collar Oil seal Bearing 1 2 2 13 12 15 40 Nm...

Page 325: ...SORBER 1 Gas pressure must be released before dis posing of a rear shock absorber To release the gas pressure drill a 2 3 mm 0 08 0 12 in hole through the rear shock absorber as shown WARNING EWA13760...

Page 326: ...4 Remove Oil seal Bearing 1 TIP Remove the bearing with a socket 2 that matches its outside diameter EAS30220 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY 1 Check Rear shock absorber rod Bends damage o R...

Page 327: ...Lubricate Collars Oil seals 2 Install Bearings 1 to the relay arm Oil seals 2 to the relay arm TIP When installing the oil seals 2 to the relay arm face the character stamp of the oil seals outside P...

Page 328: ...n installing the rear shock absorber as sembly lift up the swingarm 2 Tighten Relay arm nut Rear shock absorber assembly upper nut Connecting arm lower nut Rear shock absorber assembly lower nut Conne...

Page 329: ...4 116 1 Drive chain guard 1 2 Rear fender 1 3 Drive chain guide 1 4 Rear wheel sensor lead cover 1 5 Pivot shaft nut Washer 1 1 6 Pivot shaft ring nut Washer 1 1 7 Pivot shaft 1 8 Rear wheel sensor le...

Page 330: ...movement B by moving the swingarm up and down If the swingarm vertical movement is not smooth or if there is binding check the pivot shaft collars bearings and dust covers 4 Remove Drive chain Refer...

Page 331: ...ALLING THE SWINGARM 1 Lubricate Dust covers Pivot shaft Oil seals Collar Bushing 2 Install Bearings 1 to the swingarm Oil seals 2 to the swingarm TIP When installing the oil seals to the swingarm face...

Page 332: ...absorber assembly Refer to REAR SHOCK ABSORBER AS SEMBLY on page 4 104 Rear wheel Refer to REAR WHEEL on page 4 34 7 Adjust Drive chain slack Refer to ADJUSTING THE DRIVE CHAIN SLACK on page 3 19 A Le...

Page 333: ...1 4 Shift rod 1 5 Shift arm 1 6 Shift rod joint 2 7 Shift pedal 1 8 Drive sprocket cover 1 9 Drive chain guide 1 10 Drive sprocket nut 1 11 Washer 1 12 Drive sprocket 1 13 Drive chain 1 125 Nm 12 5 m...

Page 334: ...ngth c between the outer sides of the pins on a 15 link section of the drive chain as shown in the illustration b Calculate the length a of the 15 link section of the drive chain using the following f...

Page 335: ...O rings 1 Damage o Replace the drive chain Drive chain rollers 2 Damage wear o Replace the drive chain Drive chain side plates 3 Damage wear cracks o Replace the drive chain 5 Lubricate Drive chain E...

Page 336: ...ide of the connecting link 3 and inside of the connecting plate 1 is 14 35 14 55 mm 0 565 0 573 in 2 Lubricate Drive chain 3 Install Drive sprocket Washer 1 Drive sprocket nut 2 TIP While applying the...

Page 337: ...too loose can skip and damage the swing arm or cause an accident Therefore keep the drive chain slack within the specified lim its EAS31729 ADJUSTING THE SHIFT PEDAL TIP The shift pedal position is d...

Page 338: ...cknuts TIP Be sure to place the shift rod joints in parallel The allowable twist of the shift rod joints is 5q d Make sure the installed shift rod length is within specification Shift rod locknut 7 Nm...

Page 339: ...NSTALLING THE ROCKER ARMS AND ROCKER ARM SHAFTS 5 18 INSTALLING THE TIMING CHAIN COVER 5 18 INSTALLING THE CAMSHAFTS 5 19 CYLINDER HEAD 5 23 REMOVING THE CYLINDER HEAD 5 24 CHECKING THE CYLINDER HEAD...

Page 340: ...FT AND PULL ROD 5 59 INSTALLING THE CLUTCH 5 59 SHIFT SHAFT 5 62 CHECKING THE SHIFT SHAFT 5 63 CHECKING THE STOPPER LEVER 5 63 INSTALLING THE SHIFT SHAFT 5 63 CRANKCASE 5 64 DISASSEMBLING THE CRANKCAS...

Page 341: ...ALANCER 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 D...

Page 342: ...cylinders 4 Install Compression gauge 1 5 Measure Compression pressure Out of specification o Refer to steps c and d a Set the main switch to ON b With the throttle wide open crank the engine until t...

Page 343: ...19 Air filter case Refer to AIR FILTER CASE on page 7 4 Fuel tank Refer to FUEL TANK on page 7 1 Fuel tank cover Refer to GENERAL CHASSIS 2 on page 4 7 Rider seat Refer to GENERAL CHASSIS 1 on page 4...

Page 344: ...ge 7 1 Radiator Refer to RADIATOR on page 6 1 Oil cooler Refer to OIL COOLER on page 6 4 1 Muffler protector 1 2 Muffler joint 1 3 Muffler 1 4 Ring 1 5 Gasket 1 6 EXUP valve pulley cover 1 7 EXUP cabl...

Page 345: ...ct 15 EXUP servo motor bracket 1 16 EXUP servo motor 1 17 EXUP servo motor cover 1 12 13 11 16 17 15 10 Nm 1 0 m kgf 7 2 ft lbf 20 Nm 2 0 m kgf 14 ft lbf 25 Nm 2 5 m kgf 18 ft lbf 10 Nm 1 0 m kgf 7 2...

Page 346: ...procket Refer to CHAIN DRIVE on page 4 116 1 Clutch cable 1 Disconnect 2 Starter motor lead 1 Disconnect 3 Cylinder identification sensor coupler 1 Disconnect 4 Ignition coil coupler 4 Disconnect 5 Co...

Page 347: ...ont side 1 5 Engine mounting bolt rear upper side Engine mounting nut rear upper side 1 1 6 Engine mounting bolt rear lower side Engine mounting nut rear lower side 1 1 7 Engine 1 8 Engine mounting ad...

Page 348: ...ecification with the pivot shaft wrench Make sure that the flange on the engine mounting adjust bolt contacts the engine 7 Install Engine mounting nut rear lower side 8 Engine mounting nut rear upper...

Page 349: ...nstall Exhaust pipe Gasket 1 to exhaust chamber Muffler TIP 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 I...

Page 350: ...ator Refer to RADIATOR on page 6 1 Air cut off valve Refer to AIR INDUCTION SYSTEM on page 7 19 1 Ignition coil coupler 4 Disconnect 2 Ignition coil 4 3 Spark plug 4 If the spark plug is a new one tig...

Page 351: ...onto the mating surface and threads of the bolt If the camshaft cap bolt is a new one tighten it to 10 Nm 1 0 m kgf 7 2 ft lbf 4 Camshaft cap 2 1 If the camshaft cap bolt is a new one it is not neces...

Page 352: ...chain guide intake side 1 6 Timing chain guide exhaust side 1 7 Timing chain 1 8 Timing chain sprocket bolt 1 9 Timing chain sprocket 1 10 Straight key 1 11 Circlip 1 12 Washer 1 13 Oil seal 1 14 Oil...

Page 353: ...REMOVAL on page 5 3 Intake camshaft Exhaust camshaft Refer to CAMSHAFTS on page 5 9 1 Rocker arm shaft bolt 4 2 Straight plug rocker arm shaft 3 3 Rocker arm shaft 4 4 Rocker arm 16 1 3 10 Nm 1 0 m kg...

Page 354: ...rotor cover slot b TIP BTDC105q on the compression stroke can be found when the camshaft lobes are turned away from each other 3 Remove Timing chain tensioner 1 Timing chain tensioner gasket 4 Remove...

Page 355: ...specification o Replace the camshaft 3 Measure Camshaft runout Out of specification o Replace 3 3 3 1 2 2 3 3 1 2 Camshaft lobe dimensions Lobe height Intake 35 210 35 310 mm 1 3862 1 3902 in Limit 35...

Page 356: ...bolt is a new one tighten it to 10 Nm 1 0 m kgf 7 2 ft lbf Tighten the camshaft cap bolts in stages and in a crisscross pattern working from the inner caps out Do not turn the camshaft when measuring...

Page 357: ...to rocker arm shaft clearance TIP Calculate the clearance by subtracting the rock er arm shaft outside diameter from the rocker arm inside diameter Out of specification o Replace EAS30258 CHECKING THE...

Page 358: ...lve spring compressor 1 push and insert timing chain tensioner rod 2 into the timing chain tensioner housing TIP Push the timing chain tensioner rod in direction a and turn the timing chain tensioner...

Page 359: ...haft turns smoothly EAS31715 INSTALLING THE TIMING CHAIN COVER 1 Install Timing chain cover Timing chain cover bolt 2 Tighten Timing chain cover bolt Following the tightening order loosen the bolt one...

Page 360: ...ould be stretched and the timing chain intake side should be sagged 4 Install Camshaft cap TIP Make sure each camshaft cap is installed in its original place Refer to the identification marks as follo...

Page 361: ...turn the timing chain tensioner body 3 in direction b until it stops b Keep pressing the timing chain tensioner rod mount clip 4 into groove 5 and lock the timing chain tensioner rod c In the status...

Page 362: ...page 3 5 10 Install Timing mark accessing bolt 1 Crankshaft end cover 2 11 Install Timing chain guide top side Cylinder head cover gasket 1 Cylinder head cover gasket 2 Cylinder head cover TIP Apply T...

Page 363: ...e 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 Install the ignition coils 1 in the direction shown in the illustration Spark plug 13 Nm 1 3 m kg...

Page 364: ...er to ENGINE REMOVAL on page 5 3 Intake camshaft Exhaust camshaft Refer to CAMSHAFTS on page 5 9 1 Coolant temperature sensor 1 2 Cylinder head 1 3 Cylinder head gasket 1 4 Dowel pin 2 5 Oil delivery...

Page 365: ...s 2 Check Cylinder head Damage scratches o Replace Cylinder head water jacket Mineral deposits rust o Eliminate 3 Measure Cylinder head warpage Out of specification o Resurface the cylinder head a Pla...

Page 366: ...olt one by one and then retighten it to the specific torque and the specific angle TIP Tighten the cylinder head bolts in the tightening sequence as shown and torque them in 4 stag es 4 Install Exhaus...

Page 367: ...tainer 8 4 Exhaust valve spring 8 The valve spring is part of a set together with the valve spring seat Refer to CHECKING THE VALVE SPRINGS on page 5 32 5 Exhaust valve 8 6 Exhaust valve stem seal 8 7...

Page 368: ...g is part of a set together with the valve spring seat Refer to CHECKING THE VALVE SPRINGS on page 5 32 13 Intake valve 8 14 Intake valve stem seal 8 15 Intake valve spring seat 8 The valve spring sea...

Page 369: ...alves properly seal TIP There should be no leakage at the valve seat 1 3 Remove Valve cotters TIP Remove the valve cotters by compressing the valve spring with the valve spring compressor 1 and the va...

Page 370: ...e guide with the valve guide reamer 3 to ob tain the proper valve stem to valve guide clearance TIP After replacing the valve guide reface the valve seat Valve stem to valve guide clearance Valve guid...

Page 371: ...ck Valve seat Pitting wear o Replace the cylinder head 3 Measure Valve seat contact width a Out of specification o Replace the cylinder head a Apply blue layout fluid b onto the valve face Valve guide...

Page 372: ...o lap the valve seats and then replace them with new intake valves a Apply a coarse lapping compound a to the valve face NOTICE ECA13790 Do not let the lapping compound enter the gap between the valve...

Page 373: ...fication o Replace the valve spring and valve spring seat as a set 3 Measure Valve spring tilt a Out of specification o Replace the valve spring and valve spring seat as a set EAS31716 CHECKING THE VA...

Page 374: ...ves and related components 1 Deburr Valve stem end with an oil stone 2 Lubricate Valve stem 1 Valve stem seal 2 with the recommended lubricant 3 Install Valve spring seat 1 Valve stem seal 2 Valve 3 V...

Page 375: ...e force could damage the valve 6 Lubricate Valve pad with the recommended lubricant 7 Install Valve pad TIP Each valve pad must be reinstalled in its original position Valve spring compressor 90890 04...

Page 376: ...connect 3 Generator cover 1 4 Generator cover gasket 1 5 Dowel pin 2 6 Stator coil lead holder 1 7 Stator coil assembly stator coil crankshaft posi tion sensor 1 8 Shaft 1 9 Generator rotor 1 10 Woodr...

Page 377: ...the tapered portion of the crankshaft and the generator rotor hub When installing the generator rotor make sure the woodruff key is properly seated in the key way of the crankshaft Lubricate the washe...

Page 378: ...ific angle TIP Tighten the generator cover bolts in the tighten ing sequence as shown 5 Connect Stator coil coupler Crankshaft position sensor coupler TIP To route the stator coil lead refer to CABLE...

Page 379: ...er clutch Order Job Parts to remove Q ty Remarks Clutch housing assembly Refer to CLUTCH on page 5 53 1 Starter clutch gear 1 2 Bearing 1 3 Starter clutch assembly 1 4 Circlip 1 5 Starter clutch idle...

Page 380: ...tarter clutch operation a Install the starter clutch gear 1 onto the clutch housing assembly 2 and hold the clutch housing assembly b When turning the starter clutch gear clock wise A the starter clut...

Page 381: ...he 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 Pri...

Page 382: ...SSIS 1 on page 4 1 Fuel tank cover Refer to GENERAL CHASSIS 2 on page 4 7 Fuel tank Refer to FUEL TANK on page 7 1 Air filter case Refer to AIR FILTER CASE on page 7 4 Throttle bodies Refer to THROTTL...

Page 383: ...r motor Order Job Parts to remove Q ty Remarks 1 O ring 1 2 Starter motor front cover 1 3 Starter motor yoke 1 4 Armature assembly 1 5 Gasket 2 6 Brush holder set 1 7 Starter motor rear cover 1 1 2 3...

Page 384: ...or a Measure the armature assembly resistances with the digital circuit tester b If any resistance is out of specification re place the starter motor 4 Measure Brush length a Out of specification o Re...

Page 385: ...seal Damage wear o Replace the starter motor front cover EAS30326 ASSEMBLING THE STARTER MOTOR 1 Install Starter motor rear cover 1 Starter motor yoke 2 Starter motor front cover 3 TIP Align the matc...

Page 386: ...GING THE ENGINE OIL on page 3 30 Fuel tank Refer to FUEL TANK on page 7 1 Radiator Refer to RADIATOR on page 6 1 Oil cooler Refer to OIL COOLER on page 6 4 Exhaust pipe Muffler Refer to ENGINE REMOVAL...

Page 387: ...guide 1 9 Collar 1 10 Oil pump drive sprocket 1 11 Washer 1 12 Oil pump drive chain 1 13 Oil pump 1 14 Dowel pin 2 15 Baffle plate 1 FWD FWD 9 10 11 13 14 15 LT LT LT 10 Nm 1 0 m kgf 7 2 ft lbf 10 Nm...

Page 388: ...ing the oil pump Order Job Parts to remove Q ty Remarks 1 Oil pump cover 1 2 Dowel pin 2 3 Oil pump outer rotor 1 4 Oil pump inner rotor 1 5 Pin 1 6 Oil pump driven sprocket 1 1 2 3 4 5 6 E 10 Nm 1 0...

Page 389: ...me in stag es and in a crisscross pattern After all of the bolts are fully loosened remove them EAS30336 CHECKING THE SPROCKET AND CHAIN 1 Check Oil pump drive sprocket 1 Cracks damage wear o Replace...

Page 390: ...he defective part s 3 Check Oil pump operation Rough movement o Repeat steps 1 and 2 or replace the defective part s EAS30338 CHECKING THE RELIEF VALVE 1 Check Relief valve body 1 Relief valve 2 Sprin...

Page 391: ...ubricate Inner rotor Outer rotor Oil pump shaft with the recommended lubricant 2 Install Oil pump driven sprocket 1 Pin 2 Inner rotor 3 Outer rotor 4 Oil pump cover 5 Oil pump housing bolt TIP When in...

Page 392: ...n guide 1 4 Install O ring Oil pipe 1 1 O ring Oil delivery pipe 1 2 Oil strainer 3 O ring Relief valve assembly 4 5 Install O ring Oil delivery pipe 2 1 Oil pump drive chain guide bolt 10 Nm 1 0 m kg...

Page 393: ...one and then retighten it to the specific torque and the specific angle TIP Tighten the oil pan bolts in the tightening se quence as shown 3 Install Engine oil drain bolt Gasket Oil pan bolt 1st 6 Nm...

Page 394: ...ove Q ty Remarks Front side cowling right Refer to GENERAL CHASSIS 2 on page 4 7 Engine oil Drain Refer to CHANGING THE ENGINE OIL on page 3 30 1 Clutch cable 1 Disconnect 2 Clutch cover 1 3 Clutch co...

Page 395: ...o remove Q ty Remarks 1 Circlip 1 2 Pull lever 1 3 Pull lever spring 1 4 Circlip 1 5 Pull lever shaft 1 6 Oil seal 1 7 Bearing 1 8 Bearing 1 9 Clutch cover damper plate 1 10 Clutch cover damper 1 1 2...

Page 396: ...te 1 1 Inside diameter 110 2 mm 4 34 in 8 Clutch plate 2 8 Inside diameter 103 5 mm 4 07 in 9 Friction plate 2 7 Whitish shoe 10 Clutch damper spring 1 11 Clutch damper spring seat 1 12 Clutch boss nu...

Page 397: ...3 Remove Friction plates 1 1 4 Remove Clutch plate 1 1 Clutch plates 2 Friction plates 2 Clutch damper spring Clutch damper spring seat 5 Straighten the clutch boss nut rib a 6 Loosen Clutch boss nut...

Page 398: ...ecification o Replace the clutch plates as a set 3 Measure Assembly width a of the friction plates and clutch plates Out of specification o Adjust TIP Perform the thickness measurement without applyin...

Page 399: ...clutch housing dogs will cause er ratic clutch operation 2 Check Bearing Damage wear o Replace the bearing and clutch housing EAS30353 CHECKING THE CLUTCH BOSS 1 Check Clutch boss splines Damage pitti...

Page 400: ...g Damage wear o Replace EAS30363 INSTALLING THE CLUTCH TIP After assembling the clutch assembly the noise like a dry type clutch might occur with the gear position in neutral and half clutch This is d...

Page 401: ...ch damper spring seat Clutch damper spring Friction plates 1 Clutch plates 2 Friction plates 2 Clutch plate 1 TIP First install a friction plate and then alternate between a clutch plate and a frictio...

Page 402: ...and the specific angle TIP Tighten the clutch cover bolts in the tightening sequence as shown 8 Install Pull lever spring 1 Pull lever 2 Washer Circlip TIP The end of the pull lever should be closest...

Page 403: ...page 5 53 Shift arm Refer to CHAIN DRIVE on page 4 116 1 Circlip 1 2 Washer 1 3 Shift shaft 1 4 Washer 1 5 Circlip 1 6 Washer 1 7 Stopper lever 1 8 Stopper lever spring 1 9 Collar 1 10 Shift shaft spr...

Page 404: ...1 Shift shaft assembly Stopper lever spring 2 TIP Hook the end of the shift shaft spring 3 onto the shift shaft spring stopper 1 Hook the ends of the stopper lever spring 2 onto the stopper lever 4 an...

Page 405: ...Water pump Refer to WATER PUMP on page 6 9 Clutch housing assembly Refer to CLUTCH on page 5 53 Oil strainer Oil pump Relief valve assembly Refer to OIL PUMP on page 5 45 1 Gear position sensor 1 2 Oi...

Page 406: ...per plate upper crankcase 1 9 Clutch cable holder 1 10 Neutral switch 1 11 Gasket 1 8 9 10 11 10 Nm 1 0 m kgf 7 2 ft lbf 4 0 Nm 0 40 m kgf 2 9 ft lbf 70 Nm 7 0 m kgf 51 ft lbf 12 Nm 1 2 m kgf 8 7 ft l...

Page 407: ...gallery 2 2 Plug balancer shaft end 2 3 Lower crankcase 1 4 Dowel pin 3 10 Nm 1 0 m kgf 7 2 ft lbf 10 Nm 1 0 m kgf 7 2 ft lbf 8 Nm 0 8 m kgf 5 8 ft Ibf 24 Nm 2 4 m kgf 17 ft lbf 20 Nm 2 0 m kgf 14 ft...

Page 408: ...aring from the lower crankcase TIP Identify the position of each part very carefully so that it can be reinstalled in its original place EAS30390 CHECKING THE CRANKCASE 1 Thoroughly wash the crankcase...

Page 409: ...8 M8 u 60 mm 2 36 in bolts 19 20 M6 u 65 mm 2 56 in bolts 21 22 M6 u 70 mm 2 76 in bolt 23 M6 u 60 mm 2 36 in bolts 24 27 35 38 M6 u 50 mm 1 97 in bolts 31 34 M6 u 50 mm 1 97 in bolts LOCTITE 28 40 M6...

Page 410: ...tch 1 Oil pressure switch lead 2 TIP Apply Three Bond No 1215B to the threads a of the oil pressure switch However do not apply Three Bond No 1215B to the portion b of the oil pressure switch Install...

Page 411: ...tool with a magnet magnetized screwdrivers etc away from the gear position sensor 1 Install O ring Gear position sensor 1 TIP Lubricate the O ring with lithium soap based grease Fit the end a of the s...

Page 412: ...er to CRANKCASE on page 5 64 1 Connecting rod cap 4 2 Big end lower bearing 4 3 Big end upper bearing 4 4 Connecting rod 4 5 Piston pin clip 8 6 Piston pin 4 7 Piston 4 8 Top ring 4 9 2nd ring 4 10 Oi...

Page 413: ...nd connecting rod caps 2 Remove Piston pin clip 1 a Make sure that the piston pin clip ends are in either the a or b position in relation to the cutout c TIP If the piston pin clip ends are not positi...

Page 414: ...he piston crown Before removing the piston pin deburr the pis ton pin clip groove and the piston pin bore ar ea If both areas are deburred and the piston pin is still difficult to remove remove it wit...

Page 415: ...specification o Replace the piston and piston rings as a set TIP Before measuring the piston ring side clearance eliminate any carbon deposits from the piston ring grooves and piston rings Bore 79 00...

Page 416: ...ace the piston pin 2 Measure Piston pin bore inside diameter b Out of specification o Replace the piston 3 Calculate Piston pin to piston pin bore clearance Out of specification o Replace the piston p...

Page 417: ...tall the big end upper bearing into the con necting rod and the big end lower bearing into the connecting rod cap TIP Align the projections a on the big end bearings with the notches b in the connecti...

Page 418: ...p faces the same direction as the Y or mark b on the connecting rod Make sure the Y or marks b on the con necting rods face towards the left side of the crankshaft Install the connecting rod so that t...

Page 419: ...t of specification select replacement big end bearings 2 Select Big end bearings P1 P4 TIP The numbers A stamped into the crankshaft web and the numbers 1 on the connecting rods are used to determine...

Page 420: ...tall new bolts TIP Install by carrying out the following procedures in order to assemble in the most suitable con dition Install the new connecting rod bolt without cleaning and without any oil a Repl...

Page 421: ...n the illustration TIP When installing the first piston pin clip place oth er piston pin 2 under the piston pin as shown in the illustration TIP Align the piston pin clip end with the position a b Pus...

Page 422: ...ubricate Piston Piston rings Cylinder with the recommended lubricant 7 Offset Piston ring end gaps 8 Lubricate Crankshaft pins Connecting rod big end bearing inner surface and side surface with the re...

Page 423: ...rque wrench b Put a mark 1 on the corner of the connecting rod bolt 2 and the connecting rod cap 3 c Tighten the connecting rod bolts further to reach the specified angle 175q 185q with torque wrench...

Page 424: ...TONS 5 83 WARNING EWA17120 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...

Page 425: ...Connecting rod Refer to REMOVING THE CONNECTING RODS AND PISTONS on page 5 72 1 Balancer shaft 1 2 Balancer shaft journal lower bearing 4 3 Balancer shaft journal upper bearing 4 4 Crankshaft 1 5 Cra...

Page 426: ...s wear o Replace the crankshaft Bearing surfaces Scratches wear o Replace the crankshaft journal bearing 3 Measure Crankshaft journal to crankshaft journal bearing clearance Out of specification o Rep...

Page 427: ...arings h Measure the compressed Plastigauge width a on each crankshaft journal If the crankshaft journal to crankshaft jour nal bearing clearance is out of specification select replacement crankshaft...

Page 428: ...clearance and prevent engine damage the balancer shaft journal bearings must be installed in their original positions a Clean the balancer shaft journal bearings balancer shaft journals and bearing p...

Page 429: ...ion select replacement balancer shaft journal bearings 4 Select Balancer shaft journal bearing J1 J4 TIP The numbers A stamped into the balancer shaft web and the numbers B stamped into the lower cran...

Page 430: ...Y 1 Install Balancer shaft journal upper bearings into the upper crankcase Balancer shaft journal lower bearings into the lower crankcase TIP Align the projections a on the balancer shaft journal bear...

Page 431: ...axle assembly 1 2 Shift drum retainer 2 3 Spring 2 4 Shift fork guide bar 2 5 Shift fork L 1 6 Shift fork R 1 7 Shift drum assembly 1 8 Shift fork C 1 9 Main axle assembly 1 10 Oil delivery pipe 3 1 1...

Page 432: ...ion gear 1 2 Toothed lock washer 1 3 Toothed lock washer retainer 1 4 6th pinion gear 1 5 Collar 1 6 Washer 1 7 Circlip 1 8 3rd pinion gear 1 9 Circlip 1 10 Washer 1 11 5th pinion gear 1 12 Collar 1 1...

Page 433: ...r 1 4 1st wheel gear 1 5 Collar 1 6 5th wheel gear 1 7 Circlip 1 8 Washer 1 9 3rd wheel gear 1 10 Collar 1 11 Toothed lock washer 1 12 Toothed lock washer retainer 1 13 4th wheel gear 1 14 Collar 1 15...

Page 434: ...ing the drive axle assembly Order Job Parts to remove Q ty Remarks 19 Washer 1 20 2nd wheel gear 1 21 Collar 1 22 Collar 1 23 Oil seal 1 24 Circlip 1 25 Bearing 1 26 Drive axle 1 19 20 21 22 23 24 25...

Page 435: ...ng the bolts until the main axle assembly comes free from the upper crankcase 3 Remove Oil delivery pipe 3 1 Bearings 2 EAS30431 CHECKING THE SHIFT FORKS The following procedure applies to all of the...

Page 436: ...d dial gauge 1 Out of specification o Replace the drive axle 3 Check Transmission gears Blue discoloration pitting wear o Replace the defective gear s Transmission gear dogs Cracks damage rounded edge...

Page 437: ...iner with an axle spline and then install the toothed lock washer Be sure to align the projection on the toothed lock washer that is between the alignment marks b with the alignment mark c on the re t...

Page 438: ...m retainers 3 Bearing Oil seal Circlip 4 Drive axle assembly 5 TIP Install shift fork R into the groove a in the 5th wheel gear and shift fork L into the groove b in the 6th wheel gear on the drive ax...

Page 439: ...G 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 ASSE...

Page 440: ...LANT on page 3 33 1 Coolant reservoir hose 1 Disconnect 2 Coolant reservoir 1 3 Coolant reservoir cap 1 4 Radiator cap 1 5 Radiator fan motor coupler 2 Disconnect 6 Cooling system air bleed hose 1 Dis...

Page 441: ...h a thin flat head screwdriver 2 Check Radiator hoses Cracks damage o Replace 3 Measure Radiator cap opening pressure Below the specified pressure o Replace the radiator cap a Install the radiator cap...

Page 442: ...ed amount of the recom mended coolant Refer to CHANGING THE COOLANT on page 3 33 5 Check Cooling system Leaks o Repair or replace any faulty part a Attach the radiator cap tester 1 and radiator cap te...

Page 443: ...THE ENGINE OIL on page 3 30 1 Oil cooler cover 1 2 Damper 2 3 Oil cooler inlet hose 1 Disconnect When removing the oil cooler inlet hose also remove the water pump inlet pipe Refer to WATER PUMP on p...

Page 444: ...nstall Oil cooler 1 O ring Oil cooler bolt upper 2 Oil cooler bolt lower 3 Radiator bolt 4 TIP Apply lithium soap based grease to the O ring 2 Tighten Oil cooler bolt upper 2 3 Tighten Oil cooler bolt...

Page 445: ...ank Refer to FUEL TANK on page 7 1 Air filter case Refer to AIR FILTER CASE on page 7 4 Throttle bodies Refer to THROTTLE BODIES on page 7 9 Coolant Drain Refer to CHANGING THE COOLANT on page 3 33 1...

Page 446: ...thermo stat and thermometer s indicated tempera ture TIP If the accuracy of the thermostat is in doubt re place it A faulty thermostat could cause serious overheating or overcooling 2 Check Thermosta...

Page 447: ...n page 2 51 3 Fill Cooling system with the specified amount of the recom mended coolant Refer to CHANGING THE COOLANT on page 3 33 4 Check Cooling system Leaks o Repair or replace any faulty part Refe...

Page 448: ...HASSIS 2 on page 4 7 Fuel tank Refer to FUEL TANK on page 7 1 Radiator Refer to RADIATOR on page 6 1 Oil cooler Refer to OIL COOLER on page 6 4 Muffler Exhaust pipe Refer to ENGINE REMOVAL on page 5 3...

Page 449: ...ter pump Order Job Parts to remove Q ty Remarks 1 Water pump housing cover 1 2 O ring 1 3 Circlip 1 4 Impeller shaft 1 5 Mechanical seal 1 6 Bearing 1 7 Oil seal 1 1 2 3 4 5 6 7 10 Nm 1 0 m kgf 7 2 ft...

Page 450: ...ler shaft EAS30447 CHECKING THE WATER PUMP 1 Check Water pump housing cover 1 Impeller shaft 2 Cracks damage wear o Replace Water pump housing 3 Cracks damage wear o Replace the water pump assembly 2...

Page 451: ...al seal impeller side is flush with the impeller EAS30449 INSTALLING THE WATER PUMP 1 Install Water pump assembly 1 TIP Align the slit a on the impeller shaft with the projection b on the oil pump dri...

Page 452: ...WATER PUMP 6 13 4 Measure Radiator cap opening pressure Below the specified pressure o Replace the radiator cap Refer to CHECKING THE RADIATOR on page 6 2...

Page 453: ...7 6 INSTALLING THE INTAKE FUNNEL AND AIR FILTER CASE 7 7 CHECKING THE INTAKE FUNNEL OPERATION 7 7 INSTALLING THE SECONDARY INJECTORS 7 7 INSTALLING THE AIR FILTER CASE COVER 7 8 INSTALLING THE FUEL H...

Page 454: ...SSIS 2 on page 4 7 1 Fuel hose connector 1 Disconnect 2 Fuel pump coupler 1 Disconnect 3 Fuel tank breather hose 1 Disconnect 4 Fuel tank drain hose 1 Disconnect 5 Fuel tank 1 6 Fuel pump bracket 1 7...

Page 455: ...1 in direction b slide the fuel hose connector cover in direction c and then remove the hose from the fuel pump Before removing the hose place a few rags in the area under where it will be removed It...

Page 456: ...Temporarily tighten the rear fuel tank bolt 2 Connect Fuel hose fuel tank side NOTICE ECA17500 When installing the fuel hose make sure that it is securely connected and that the fuel hose connector co...

Page 457: ...Disconnect 3 Fuel rail Secondary injector joint 2 1 4 Secondary injector 4 5 Air filter case cover 1 6 Air filter element 1 7 Intake funnel assembly bolt 6 Loosen 8 Crankcase breather hose 1 Disconnec...

Page 458: ...ss the two buttons 2 on the sides of the connector and then remove the hose Before removing the hose place a few rags in the area under where it will be removed EAS30460 REMOVING THE SECONDARY INJECTO...

Page 459: ...from air filter case NOTICE ECA22590 Do not remove the bolts 1 from the intake funnel joint EAS30462 CHECKING THE SECONDARY INJECTORS 1 Check Injectors Obstruction o Replace and check the fuel pump f...

Page 460: ...funnels should move smoothly and should not make any unusual sound EAS30466 INSTALLING THE SECONDARY INJECTORS NOTICE ECA21550 Always use new O rings When installing the injectors do not allow any fo...

Page 461: ...njector joint side NOTICE ECA17500 When installing the fuel hose make sure that it is securely connected and that the fuel hose connector cover on the fuel hose is in the correct position otherwise th...

Page 462: ...17 1 Cross bar 1 2 Throttle position sensor coupler 1 Disconnect 3 Intake air pressure sensor coupler 1 Disconnect 4 Throttle servo motor coupler 1 Disconnect 5 Accelerator position sensor coupler 1...

Page 463: ...ew 4 Loosen 12 Throttle body assembly 1 13 Neutral switch connector 1 Disconnect 14 Coolant temperature sensor coupler 1 Disconnect 15 Heat protector 1 16 Throttle body joint 2 11 12 13 14 15 16 LT 23...

Page 464: ...ose joint 2 3 Intake air pressure sensor 1 4 Accelerator position sensor 1 5 Throttle position sensor 1 6 Fuel rail 2 7 Primary injector joint 1 8 Primary injector 4 1 2 3 4 5 6 7 8 3 5 Nm 0 35 m kgf...

Page 465: ...fer to CHECKING THE FUEL INJEC TORS on page 8 196 EAS30769 CHECKING AND CLEANING THE THROTTLE BODIES TIP Clean the throttle bodies only if they cannot be synchronized using the bypass air screws Be fo...

Page 466: ...arbon 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 NOTICE ECA17590 Do not use a tool such as a wire brus...

Page 467: ...ive force replace it If installing the original fuel rail and bolts remove the white paint marks using a cleaning solvent Otherwise paint chips on the bolt seats could prevent the bolts from being tig...

Page 468: ...ank bolts and hold up the fuel tank b Disconnect the fuel hose 1 from the fuel pump Refer to FUEL TANK on page 7 1 WARNING EWA17320 Cover fuel hose connections with a cloth when disconnecting them Res...

Page 469: ...in switch to OFF e Simultaneously press and hold the up button 1 and center button 2 turn the main switch to ON and continue to press the buttons for 8 seconds more TIP ECU 3 appears on the display f...

Page 470: ...Temporary tighten the accelerator position sensor b Check that the throttle valves are fully closed c Connect the accelerator position sensor to the wire harness d Connect the throttle cables to the...

Page 471: ...o Select the diagnostic code number 15 p Turn the throttle grip to the fully closed posi tion q Check the meter display value If the meter display value is not 10 24 adjust the acceler ator position...

Page 472: ...AIR INDUCTION SYSTEM 7 19 EAS20071 AIR INDUCTION SYSTEM...

Page 473: ...CTION SYSTEM 7 20 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 val...

Page 474: ...ter case Refer to AIR FILTER CASE on page 7 4 Throttle bodies Refer to THROTTLE BODIES on page 7 9 Radiator Refer to RADIATOR on page 6 1 1 Atmospheric pressure sensor coupler 1 Disconnect 2 Immobiliz...

Page 475: ...cut off valve 1 9 Air induction system hose air cut off valve to reed valve cover 1 10 Air induction system hose air cut off valve to reed valve cover 1 11 Air cut off valve 1 12 Reed valve cover 2 1...

Page 476: ...in accordance with the combus tion conditions Ordinarily the air cut off valve opens to allow the air to flow during idle and closes to cut off the flow when the vehicle is be ing driven However if th...

Page 477: ...STALLING THE AIR INDUCTION SYSTEM 1 Install Reed valve plate TIP Align the projection a on the cylinder head cov er 1 with the hole b in the reed valve plate 2 Install Reed valve assembly TIP Install...

Page 478: ...AIR INDUCTION SYSTEM 7 25...

Page 479: ...ALING SYSTEM 8 29 CIRCUIT DIAGRAM 8 29 TROUBLESHOOTING 8 33 COOLING SYSTEM 8 39 CIRCUIT DIAGRAM 8 39 TROUBLESHOOTING 8 43 FUEL INJECTION SYSTEM 8 45 CIRCUIT DIAGRAM 8 45 ECU SELF DIAGNOSTIC FUNCTION 8...

Page 480: ...RCUIT DIAGRAM 8 153 MAINTENANCE OF THE SCU Suspension Control Unit 8 155 SCU Suspension Control Unit SELF DIAGNOSTIC FUNCTION 8 155 TROUBLESHOOTING METHOD SCU 8 155 BASIC INSTRUCTIONS FOR DIAGNOSTIC F...

Page 481: ...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...

Page 482: ...W R W R W R W L G L G R W R W R W R W R W R W R W R W R W R W R W R W R W R W R W R W R W R W R W R W R W R W R W R G R G R G R G R G R G R G R W R W R W R W B B B B B B B B L L Br Y Br Y B B R W R W...

Page 483: ...ebar 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...

Page 484: ...B B B B B B G L G L G L G L B B B B B B B B G Y G Y G Y G Y Gy G Gy G Gy R Gy R Gy B Gy B Gy Gy R L R W R W R G R G B W B W L B L B L W L W L W L W L W L W L B L B L B L B B W B W R G O O W W Y Y B B...

Page 485: ...ebar 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...

Page 486: ...is open However the engine continues to run under the following conditions The transmission is in gear the neutral switch is open and the sidestand is up the sidestand switch circuit is closed The tra...

Page 487: ...Refer to CHECKING THE SPARK PLUGS on page 3 4 NGo Re gap or replace the spark plug s OKp 4 Check the ignition spark gap Refer to CHECKING THE SPARK PLUGS on page 3 4 OKo Ignition system is OK NGp 5 C...

Page 488: ...Check the sidestand switch Refer to CHECKING THE SWITCHES on page 8 177 NGo Replace the sidestand switch OKp 12 Check the relay unit diode Refer to CHECKING THE RELAY UNIT DIODE on page 8 185 NGo Rep...

Page 489: ...IGNITION SYSTEM 8 8...

Page 490: ...G Gy G R W R W R W R W L G L G R W R W R W R W R W R W R W R W R W R W R W R W R W R W R W R W R W R W R W R W R W R W R W R G R G R G R G R G R G R G R W R W R W R W B B B B B B B B L L Br Y Br Y B...

Page 491: ...oupler 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 Sidestan...

Page 492: ...B B B B B B B B B G L G L G L G L B B B B B B B B G Y G Y G Y G Y Gy G Gy G Gy R Gy R Gy B Gy B Gy Gy R L R W R W R G R G B W B W L B L B L W L W L W L W L W L W L B L B L B L B B W B W R G O O W W Y...

Page 493: ...oupler 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 Sidestan...

Page 494: ...rating when neither of these condi tions has been met In this instance the starting circuit cut off relay is open so current cannot reach the starter motor When at least one of the above conditions ha...

Page 495: ...ation Refer to CHECKING THE START ER MOTOR OPERATION on page 8 187 OKo Starter motor is OK Perform the electric starting system troubleshooting starting with step 5 NGp 4 Check the starter motor Refer...

Page 496: ...heck the clutch switch Refer to CHECKING THE SWITCHES on page 8 177 NGo Replace the clutch switch OKp 12 Check the start engine stop switch Refer to CHECKING THE SWITCHES on page 8 177 NGo Replace the...

Page 497: ...ELECTRIC STARTING SYSTEM 8 16...

Page 498: ...W Br L B W B W B Y B R R R R R R R R Br L Br L Br L Br L L Y L Y B Y B Y B L R R R R G B L R L R L W L W R B Br W Br W L R L R B B B W L W Y R W R W R W R L R W R Y R W R W L R L R R W L W R L L W L...

Page 499: ...CHARGING SYSTEM 8 18 1 AC magneto 2 Rectifier regulator 4 Main fuse 19 Battery 20 Engine ground...

Page 500: ...B Y B L R R R R G B L R L R L W L W R B Br W Br W L R L R B B B W L W Y R W R W R W R L R W R Y R W R W L R L R R W L W R L L W L B L B L Y B Y R W R R R W R W R W R W R W R W R W R W R W R W R W R W...

Page 501: ...CHARGING SYSTEM 8 20 1 AC magneto 2 Rectifier regulator 4 Main fuse 19 Battery 20 Engine ground...

Page 502: ...to CHECKING AND CHARGING THE BATTERY on page 8 181 NGo Clean the battery terminals Recharge or replace the battery OKp 3 Check the stator coil Refer to CHECKING THE STA TOR COIL on page 8 187 NGo Repl...

Page 503: ...CHARGING SYSTEM 8 22...

Page 504: ...W R W R W R W L G L G R W R W R W R W R W R W R W R W R W R W R W R W R W R W R W R W R W R W R W R W R W R W R W R G R G R G R G R G R G R G R W R W R W R W B B B B B B B B L L Br Y Br Y B B R W R W...

Page 505: ...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 Dimm...

Page 506: ...B B B B B B B G L G L G L G L B B B B B B B B G Y G Y G Y G Y Gy G Gy G Gy R Gy R Gy B Gy B Gy Gy R L R W R W R G R G B W B W L B L B L W L W L W L W L W L W L B L B L B L B B W B W R G O O W W Y Y B...

Page 507: ...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 Dimm...

Page 508: ...lean the battery terminals Recharge or replace the battery OKp 3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 177 NGo Replace the main switch immobilizer unit OKp 4 Check the dimmer...

Page 509: ...LIGHTING SYSTEM 8 28...

Page 510: ...R W R W R W R W L G L G R W R W R W R W R W R W R W R W R W R W R W R W R W R W R W R W R W R W R W R W R W R W R W R G R G R G R G R G R G R G R W R W R W R W B B B B B B B B L L Br Y Br Y B B R W R...

Page 511: ...nsor 60 Joint connector 67 Coolant temperature sensor 75 Gear position sensor 76 Meter assembly 78 Fuel level warning light 79 Neutral indicator light 80 Shift timing indicator light 81 Multi function...

Page 512: ...B B B B B B B G L G L G L G L B B B B B B B B G Y G Y G Y G Y Gy G Gy G Gy R Gy R Gy B Gy B Gy Gy R L R W R W R G R G B W B W L B L B L W L W L W L W L W L W L B L B L B L B B W B W R G O O W W Y Y B...

Page 513: ...nsor 60 Joint connector 67 Coolant temperature sensor 75 Gear position sensor 76 Meter assembly 78 Fuel level warning light 79 Neutral indicator light 80 Shift timing indicator light 81 Multi function...

Page 514: ...backup ABS control unit and haz ard lighting Refer to CHECKING THE FUSES on page 8 180 NGo Replace the fuse s OKp 2 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 181 NGo Clean...

Page 515: ...e rear brake light switch Refer to CHECKING THE SWITCHES on page 8 177 NGo Replace the rear brake light switch OKp 3 Check the entire signaling system s wiring Refer to CIRCUIT DIAGRAM on page 8 29 NG...

Page 516: ...ling system s wiring OKp Replace the meter assembly 1 Check the entire signaling system s wiring Refer to CIRCUIT DIAGRAM on page 8 29 NGo Properly connect or replace the wiring har ness OKp 2 Disconn...

Page 517: ...rature sensor OKp 2 Check the entire signaling system s wiring Refer to CIRCUIT DIAGRAM on page 8 29 NGo Properly connect or replace the wiring har ness OKp Replace the ECU or meter assembly Refer to...

Page 518: ...ce the shift switch OKp 6 Check the neutral switch Refer to DIAGNOSTIC CODE SENSOR OPERATION TABLE on page 9 7 and CHECKING THE SWITCHES on page 8 177 NGo Replace the neutral switch OKp 7 Check the en...

Page 519: ...SIGNALING SYSTEM 8 38...

Page 520: ...W R W R W R W L G L G R W R W R W R W R W R W R W R W R W R W R W R W R W R W R W R W R W R W R W R W R W R W R W R G R G R G R G R G R G R G R W R W R W R W B B B B B B B B L L Br Y Br Y B B R W R W...

Page 521: ...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 te...

Page 522: ...B B B B B B G L G L G L G L B B B B B B B B G Y G Y G Y G Y Gy G Gy G Gy R Gy R Gy B Gy B Gy Gy R L R W R W R G R G B W B W L B L B L W L W L W L W L W L W L B L B L B L B B W B W R G O O W W Y Y B B...

Page 523: ...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 te...

Page 524: ...ck the main switch Refer to CHECKING THE SWITCHES on page 8 177 NGo Replace the main switch immobilizer unit OKp 4 Check the radiator fan motor Refer to CHECKING THE RADIA TOR FAN MOTORS on page 8 190...

Page 525: ...COOLING SYSTEM 8 44...

Page 526: ...Gy G R W R W R W R W L G L G R W R W R W R W R W R W R W R W R W R W R W R W R W R W R W R W R W R W R W R W R W R W R W R G R G R G R G R G R G R G R W R W R W R W B B B B B B B B L L Br Y Br Y B B R...

Page 527: ...ary injector 4 52 Accelerator position sensor 53 Throttle position sensor 54 Intake funnel servo motor 55 Throttle servo motor 56 Steering damper solenoid 57 ABS ECU Electronic Control Unit 58 Front w...

Page 528: ...B B B B B B B B G L G L G L G L B B B B B B B B G Y G Y G Y G Y Gy G Gy G Gy R Gy R Gy B Gy B Gy Gy R L R W R W R G R G B W B W L B L B L W L W L W L W L W L W L B L B L B L B B W B W R G O O W W Y Y...

Page 529: ...ector 4 52 Accelerator position sensor 53 Throttle position sensor 54 Intake funnel servo motor 55 Throttle servo motor 56 Steering damper solenoid 57 ABS ECU Electronic Control Unit 58 Front wheel se...

Page 530: ...remains stored in the memory of the ECU until it is deleted Engine trouble and system warning light indication and fuel injection system operation The warning light flashes when any one of the follow...

Page 531: ...ouble and system warning light comes on 1 Check Fault code number a Check the fault code number displayed on the meter b Identify the faulty system with the fault code number c Identify the probable c...

Page 532: ...e main switch to ON and continue to press the buttons for 8 seconds or more TIP ECU appears on the display 4 Simultaneously press the up button and center button for 2 seconds or more 5 While DIAG is...

Page 533: ...d in this manual as follows If a diagnostic code number has a corresponding fault code number the information is shown in TROUBLESHOOTING DETAILS ECU Refer to TROUBLESHOOTING DETAILS ECU on page 8 54...

Page 534: ...the operation of the multi function meter and indicators will be different from the normal operation Yamaha diagnostic tool 90890 03239 Fault diagnosis mode Fault codes recorded on the ECU are read an...

Page 535: ...e number is not dis played o Service is finished Fault code number is displayed o Go to item 2 2 Connection of wire harness ECU coupler Check the locking condition of the coupler Disconnect the couple...

Page 536: ...king condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Improperly connected o Con nect the coupler securely or replace the w...

Page 537: ...of the pins Improperly connected o Con nect the coupler securely or replace the wire harness Crank the engine Fault code number is not dis played o Service is finished Fault code number is displayed...

Page 538: ...y Displays the intake air pressure Procedure Operate the throttle while pushing the side of the start engine stop switch If the display value changes the performance is OK Item Probable cause of malfu...

Page 539: ...t code number is displayed o Go to item 5 5 Defective intake air pressure sensor Execute the diagnostic mode Code No 03 When engine is stopped Atmospheric pressure at the current altitude and weather...

Page 540: ...condition Clogged or detached hose o Repair or replace the sensor hose Start the engine and let it idle for approximately 5 seconds Fault code number is not dis played o Service is finished Fault code...

Page 541: ...harness ECU coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Improperly connected o Con nect the...

Page 542: ...THE ECU Engine Control Unit on page 8 180 Fault code No 17 Item EXUP servo motor open or short circuit detected Fail safe system Able to start engine Able to drive vehicle Diagnostic code No 53 Actua...

Page 543: ...blue Turn the main switch to ON Fault code number is not dis played o Service is finished Fault code number is displayed o Go to item 4 4 Defective EXUP servo motor Execute the diagnostic mode Code N...

Page 544: ...upler and ECU coupler black green black green black red black red Turn the main switch to ON Fault code number is not dis played o Service is finished Fault code number is displayed o Go to item 4 4 D...

Page 545: ...urely or replace the wire harness Turn the main switch to ON and then extend and retract the sidestand Fault code number is not dis played o Service is finished Fault code number is displayed o Go to...

Page 546: ...AKE AIR PRESSURE SEN SOR on page 8 194 Turn the main switch to ON Fault code number is not dis played o Service is finished Fault code number is displayed o Go to item 2 2 Defective atmospheric pressu...

Page 547: ...coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Improperly connected o Con nect the coupler sec...

Page 548: ...actually measured air temperature with the meter display value Item Probable cause of malfunction and check Maintenance job Confirmation of service com pletion 1 Connection of intake air temper ature...

Page 549: ...te the diagnostic mode Code No 05 When engine is cold Displayed temperature is close to the ambient temperature The displayed temperature is not close to the ambient temper ature o Check the intake ai...

Page 550: ...ue Between joint connector and ECU coupler black blue black blue Turn the main switch to ON Fault code number is not dis played o Service is finished Fault code number is displayed o Go to item 4 4 In...

Page 551: ...Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Improperly connected o Con nect the coupler securely or...

Page 552: ...hed Fault code number is displayed o Go to item 6 6 Defective O2 sensor 1 Check the O2 sensor 1 Replace if defective Refer to ENGINE REMOVAL on page 5 3 Start the engine warm it up and then race it or...

Page 553: ...r to REPLACING THE ECU Engine Control Unit on page 8 180 Fault code No 33 Item Cylinder 1 ignition coil open or short circuit detected in the pri mary lead of the cylinder 1 ignition coil Fail safe sy...

Page 554: ...r is displayed o Go to item 5 5 Defective cylinder 1 ignition coil Measure the primary coil resis tance of the cylinder 1 ignition coil Replace if out of specification Refer to CHECKING THE IGNITION C...

Page 555: ...o Go to item 4 4 Installed condition of cylinder 2 ignition coil Check for looseness or pinch ing Improperly installed ignition coil o Reinstall or replace the igni tion coil Start the engine and let...

Page 556: ...range green orange green Start the engine and let it idle for approximately 5 seconds Fault code number is not dis played o Service is finished Fault code number is displayed o Go to item 4 4 Installe...

Page 557: ...dis played o Service is finished Fault code number is displayed o Go to item 3 3 Wire harness continuity Open or short circuit o Replace the wire harness Between cylinder 4 ignition coil coupler and...

Page 558: ...tor 4 five times at one second intervals Illuminates the engine trouble and system warning light Procedure Check that primary injector 4 is actuated five times by listening for the operating sound Ite...

Page 559: ...injector 1 red black red black red blue red blue Primary injector 2 green black green black red blue red blue Primary injector 3 blue black blue black red blue red blue Primary injector 4 orange black...

Page 560: ...e coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Improperly connected o Con nect the coupler securely or replace the wire harness Execute...

Page 561: ...nertial Measurement Unit no normal signals are received from the IMU Inertial Measurement Unit Fail safe system Unable to start engine Unable to drive vehicle Diagnostic code No 17 Meter display Displ...

Page 562: ...tch to ON Fault code number is not dis played o Service is finished Fault code number is displayed o Go to item 5 5 Defective IMU Execute the diagnostic mode Code No 17 Check that 0 5q is displayed wh...

Page 563: ...lue increases o Go to item A 8 and delete the fault code Value does not increase o Go to item A 3 A 3 Connection of ABS ECU cou pler Check the locking condition of the coupler Disconnect the coupler a...

Page 564: ...t code A 8 Delete the fault code Turn the main switch to ON and then rotate the rear wheel by hand Start the engine and input the vehicle speed signals by operat ing the vehicle at 20 to 30 km h 19 mi...

Page 565: ...t indication o Go to item B 9 Incorrect indication o Go to item B 3 B 3 Connection of wire harness ECU coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent...

Page 566: ...area Malfunction o Replace the shift drum Refer to TRANSMISSION on page 5 90 Execute the diagnostic mode Code No 21 When the transmission is in neutral ON When the transmission is in gear with the cl...

Page 567: ...Execute the diagnostic mode Code No 07 Rotate the rear wheel by hand and check that the indicated value increases Value does not increase o Go to item A 2 for the rear wheel sensor Execute the diagno...

Page 568: ...transmission in gear and when the sidestand is retracted ON Correct indication o Go to item C 8 Incorrect indication o Go to item C 5 C 5 Wire harness continuity Open or short circuit o Replace the w...

Page 569: ...splay value If the actually measured battery voltage is low recharge the battery 50 Actuation Actuates the relay unit five times at one second intervals Illuminates the engine trouble and system warni...

Page 570: ...ng sound o Replace the relay unit Start the engine and let it idle for approximately 5 seconds Fault code number is not dis played o Service is finished Fault code number is displayed o Go to item 5 5...

Page 571: ...ion of cylinder 2 Change the CO concentration of cylinder 2 and rewrite in EEPROM Refer to ADJUSTING THE EXHAUST GAS VOLUME on page 3 12 After this adjustment is made the memory is not recovered when...

Page 572: ...page 8 180 Fault code No 45 Item Malfunction in ECU internal circuit power source self cut off does not work Fail safe system Able Unable to start engine Able Unable to drive vehicle Diagnostic code N...

Page 573: ...ber is not dis played o Service is finished Fault code number is displayed o Go to item 5 5 Malfunction in ECU Replace the ECU Refer to REPLACING THE ECU Engine Control Unit on page 8 180 Fault code N...

Page 574: ...throttle grip in fully open position 15 Meter display Accelerator position sensor signal 2 10 24 fully closed position 95 109 fully open position Procedure Check with throttle grip in fully closed pos...

Page 575: ...t code number is not dis played o Service is finished Fault code number is displayed o Go to item 6 6 Defective accelerator position sensor Check accelerator position sen sor signal 1 Execute the diag...

Page 576: ...h to ON Fault code number is not dis played o Service is finished Fault code number is displayed o Go to item 4 4 Wire harness continuity Open or short circuit o Replace the wire harness Between throt...

Page 577: ...number is displayed o Go to item 2 2 Connection of wire harness ECU coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking co...

Page 578: ...3 3 Connection of wire harness ECU coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Improperly c...

Page 579: ...malfunction and check Maintenance job Confirmation of service com pletion 1 Locate the malfunction If the ABS warning light is on refer to BASIC INSTRUC TIONS FOR TROUBLESHOOT ING on page 8 128 If the...

Page 580: ...ack white white Between ABS ECU coupler and ECU coupler gray black gray black Execute the diagnostic mode Code No 16 Rotate the front wheel by hand and check that the indicated value increases Value i...

Page 581: ...of wire harness ECU coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Improperly connected o Con...

Page 582: ...condition of the pins Improperly connected o Con nect the coupler securely or replace the wire harness Turn the main switch to ON Fault code number is not dis played o Service is finished Fault code...

Page 583: ...tion of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Improperly connected o Con nect the coupler securely or replace the wire harnes...

Page 584: ...R W R W R W R W L G L G R W R W R W R W R W R W R W R W R W R W R W R W R W R W R W R W R W R W R W R W R W R W R W R G R G R G R G R G R G R G R W R W R W R W B B B B B B B B L L Br Y Br Y B B R W R...

Page 585: ...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 p...

Page 586: ...B B B B B B B G L G L G L G L B B B B B B B B G Y G Y G Y G Y Gy G Gy G Gy R Gy R Gy B Gy B Gy Gy R L R W R W R G R G B W B W L B L B L W L W L W L W L W L W L B L B L B L B B W B W R G O O W W Y Y B...

Page 587: ...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 p...

Page 588: ...3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 177 NGo Replace the main switch immobilizer unit OKp 4 Check the start engine stop switch Refer to CHECKING THE SWITCHES on page 8 177...

Page 589: ...FUEL PUMP SYSTEM 8 108...

Page 590: ...G R W R W R W R W L G L G R W R W R W R W R W R W R W R W R W R W R W R W R W R W R W R W R W R W R W R W R W R W R W R G R G R G R G R G R G R G R W R W R W R W B B B B B B B B L L Br Y Br Y B B R W...

Page 591: ...ch 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 ind...

Page 592: ...B B B B B B B B G L G L G L G L B B B B B B B B G Y G Y G Y G Y Gy G Gy G Gy R Gy R Gy B Gy B Gy Gy R L R W R W R G R G B W B W L B L B L W L W L W L W L W L W L B L B L B L B B W B W R G O O W W Y Y...

Page 593: ...ch 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 ind...

Page 594: ...lost regis tering new codes in the standard keys is impossible The standard keys can still be used to start the vehicle However if code re registering is required e g if a new standard key is made or...

Page 595: ...the ignition key to OFF 30 seconds later the indicator light will start flashing continuously in the standby flashing mode pattern for up to 24 hours After that time the indicator light will stop flas...

Page 596: ...le the indicator light is flashing turn the main switch to OFF remove the key and within 5 sec onds insert the second standard key to be registered into the main switch TIP If he immobilizer system in...

Page 597: ...in 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...

Page 598: ...immobilizer sys tem wiring Refer to CIRCUIT DIAGRAM on page 8 109 NGo Properly connect or repair the immobilizer system wiring OKp Check the condition of the each im mobilizer system circuits Refer t...

Page 599: ...h Noise interference or dis connected lead cable 1 Interference due to radio wave noise 2 Disconnected commu nication harness 3 Immobilizer unit mal function 4 ECU failure The ECU or immobi lizer unit...

Page 600: ...Gy G Gy G R W R W R W R W L G L G R W R W R W R W R W R W R W R W R W R W R W R W R W R W R W R W R W R W R W R W R W R W R W R G R G R G R G R G R G R G R W R W R W R W B B B B B B B B L L Br Y Br Y...

Page 601: ...Handlebar switch right 26 Front brake light switch 37 ECU Engine Control Unit 57 ABS ECU Electronic Control Unit 58 Front wheel sensor 59 Rear wheel sensor 60 Joint connector 61 Yamaha diagnostic tool...

Page 602: ...L B B B B B B B B B G L G L G L G L B B B B B B B B G Y G Y G Y G Y Gy G Gy G Gy R Gy R Gy B Gy B Gy Gy R L R W R W R G R G B W B W L B L B L W L W L W L W L W L W L B L B L B L B B W B W R G O O W W...

Page 603: ...bar switch right 26 Front brake light switch 37 ECU Engine Control Unit 57 ABS ECU Electronic Control Unit 58 Front wheel sensor 59 Rear wheel sensor 60 Joint connector 61 Yamaha diagnostic tool coupl...

Page 604: ...ABS Anti lock Brake System 8 123 EAS30525 ABS COMPONENTS CHART 1 2 5 6 7 8 9 10 11 12 3 4 1...

Page 605: ...sembly 2 ABS warning light 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...

Page 606: ...ABS Anti lock Brake System 8 125 EAS30844 ABS COUPLER LOCATION CHART 2 1 3 4 5...

Page 607: ...ABS Anti lock Brake System 8 126 1 Meter assembly coupler 2 Front wheel sensor coupler 3 ABS ECU coupler 4 Yamaha diagnostic tool coupler 5 Rear wheel sensor coupler...

Page 608: ...low the normal service method WARNING EWA16710 When maintenance or checks have been performed on components related to the ABS be sure to perform a final check before delivering the vehicle to the cus...

Page 609: ...memory of the ABS ECU Delete the fault codes when the ser vice is finished This is because the past fault codes will be displayed again if another malfunction occurs EAS30529 BASIC INSTRUCTIONS FOR T...

Page 610: ...hecks Were all of the final checks completed normally Finished Yes No A Turn the main switch to ON and check the ABS warning light Fails to come on Comes on The ABS ECU fuse is blown The ABS ECU coupl...

Page 611: ...t comes on the ABS ECU is defective Replace the hydraulic unit assembly EAS30533 A 2 THE ABS WARNING LIGHT AND OTHER INDICATOR LIGHTS FAIL TO COME ON 1 Main switch Check the main switch for continuity...

Page 612: ...inal of the Yamaha diagnostic tool coupler CANL 4 ABS ECU malfunction Replace the hydraulic unit assembly EAS31164 A 5 ABS ECU AND FI ECU FAIL TO COMMUNICATE 1 Yamaha diagnostic tool Check that the Ya...

Page 613: ...on points after terminating the connection with the Yamaha diagnostic tool and turning the main switch off Operation of the Yamaha diagnostic tool Fault diagnosis mode Malfunction results are displaye...

Page 614: ...oint 11 Front wheel sensor intermit tent pulses or no pulses Front wheel sensor signal is not received properly Pulses are not received or are received intermittently while the vehicle is traveling Fo...

Page 615: ...he front wheel sensor and the hydraulic unit assembly Open or short circuit in the wire harness between the front wheel sensor and the hydraulic unit assembly Defective front wheel sen sor or hydrauli...

Page 616: ...nter mittently while the vehicle is traveling Rear wheel will not recover from the locking tendency even though the signal is transmitted from the ABS ECU to reduce the hydrau lic pressure Incorrect i...

Page 617: ...cted in pressure sensor power sup ply circuit of hydraulic unit assembly Defective hydraulic unit assembly 63 Defective front pressure sen sor Abnormality detected in pressure sensor circuit at front...

Page 618: ...Symptom Front wheel sensor signal is not received properly Pulses are not received or are received intermittently while the vehicle is travel ing Order Item components and probable cause Check or mai...

Page 619: ...condition of the sensor Repair or replace the wheel sensor if necessary Refer to MAINTENANCE OF THE REAR WHEEL SENSOR AND SENSOR ROTOR on page 4 40 Fault code No 13 26 Item Front wheel sensor abnorma...

Page 620: ...el sensor if necessary 2 Incorrect installation of the rear wheel Check the components for looseness distortion and bends Refer to CHECKING THE REAR WHEEL on page 4 38 3 Defective sensor rotor or inco...

Page 621: ...Wheel sensor 3 Defective front wheel sensor or hydraulic unit assembly If the above items were performed and no malfunctions were found the wheel sensor or hydraulic unit assembly is defective Replac...

Page 622: ...e is short circuit the wire harness is defective Replace the wire harness 6 ABS ECU 7 Wheel sensor 3 Defective rear wheel sensor or hydraulic unit assembly If the above items were performed and no mal...

Page 623: ...place the hydraulic unit assembly Refer to ABS Anti lock Brake System on page 4 65 Fault code No 33 Item Hydraulic unit assembly abnormal ABS motor power supply Symptom Power is not supplied to the mo...

Page 624: ...d from the ABS ECU to reduce the hydraulic pressure Order Item components and probable cause Check or maintenance job 1 Incorrect installation of the front wheel sensor Check the components for loosen...

Page 625: ...embly If the above items were performed and no malfunctions were found replace the hydraulic unit assembly Refer to ABS Anti lock Brake System on page 4 65 Fault code No 43 45 Item Front wheel sensor...

Page 626: ...THE REAR WHEEL on page 4 38 3 Defective sensor rotor or incorrect instal lation of the rotor Check the surface of the sensor rotor for damage Replace the sensor rotor if there is visible damage Refer...

Page 627: ...ler 3 Open or short circuit in the wire harness between the battery and the hydraulic unit assembly Replace if there is an open or short circuit Between ABS ECU coupler and ABS ECU fuse red black red...

Page 628: ...the coupler for any pins that may be pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect the cou pler securely TIP Turn the main switch to OFF before...

Page 629: ...brake line and if there is bending or blocking replace the rear brake line 2 Defective hydraulic unit assembly Replace the hydraulic unit assembly Refer to ABS Anti lock Brake System on page 4 65 Fau...

Page 630: ...er assembly and joint coupler blue white blue white blue black black blue Between joint coupler and ABS ECU coupler blue white blue white blue black black blue 3 Defective meter assembly Replace the m...

Page 631: ...nit assembly Symptom Transmitted data from the IMU cannot be normally received Order Item components and probable cause Check or maintenance job 1 Defective coupler between the IMU and the hydraulic u...

Page 632: ...routing confirmation Refer to HYDRAULIC UNIT OPERATION TEST on page 4 70 If it does not have reaction force properly the brake hose is not properly routed or connected 4 Delete the fault codes Refer t...

Page 633: ...ABS Anti lock Brake System 8 152...

Page 634: ...P W P L P L B W B W L Y L Y L Y Br Y Br Y L R L R W W L B B B B B B B B B G L G L G L G L B B B B B B B B G Y G Y G Y G Y Gy G Gy G Gy R Gy R Gy B Gy B Gy Gy R L R W R W R G R G B W B W L B L B L W L...

Page 635: ...le and system warning light 113 SCU fuse 114 SCU Suspension Control Unit 115 Front fork stepping motor left 116 Front fork stepping motor right 117 Rear shock absorber assembly stepping motor compress...

Page 636: ...merical order starting with the lowest number Once a fault code has been displayed it remains stored in the memory of the SCU until it is deleted Checking the engine trouble and system warning light T...

Page 637: ...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 5...

Page 638: ...e com pletion 1 Connection of ECU coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Improperly con...

Page 639: ...cuit o Replace the wire harness Between SCU coupler and joint coupler blue white blue white blue black blue black Between the joint coupler and ABS ECU coupler blue white blue white blue black blue bl...

Page 640: ...inished Fault code No 46 Item Abnormal SCU power supply voltage Fail safe system Able to start engine Able to drive vehicle Diagnostic code No 09 Indicated Displays the SCU power supply voltage Approx...

Page 641: ...d o Con nect the coupler securely or replace the wire harness Turn the main switch to OFF and back to ON and check the warning light The warning light does not come on o Service is finished The warnin...

Page 642: ...black black gray red black gray green black Between stepping motor 1 and power battery 3 gray brown white gray black brown white gray red brown white gray green brown white Turn the main switch to OF...

Page 643: ...and 4 Specified resistance 14 8 18 2 When the motor is cold at 20 qC 68 qF Out of specification o Go to step e e Stepping motor is defective o Replace Turn the main switch to ON Fault code number is n...

Page 644: ...to OFF and back to ON and check the warning light The warning light does not come on o Service is finished The warning light comes on o Go to item 3 3 Malfunction in meter assembly Replace the meter...

Page 645: ...o Replace the wire harness Between SCU coupler and left front fork stepping motor green green green black green black green red green red green blue green blue Between SCU coupler and right front fork...

Page 646: ...or 3 and power bat tery 6 pink brown white pink black brown white pink white brown white pink blue brown white Between rear shock absorber assembly stepping motor compression damping 4 and power batte...

Page 647: ...d Measure the resistance of the stepping motor between 3 and 4 Specified resistance 14 8 18 2 When the motor is cold at 20 qC 68 qF Out of specification o Go to step e e Stepping motor is defective o...

Page 648: ...e Diagnostic code No Indicated Procedure Item Probable cause of malfunction and check Maintenance job Confirmation of service com pletion 1 Connection of IMU coupler Check the locking condition of the...

Page 649: ...system was not performed Fail safe system Unable to start engine Able Unable to drive vehicle Diagnostic code No Indicated Procedure Item Probable cause of malfunction and check Maintenance job Confi...

Page 650: ...B W L Y L Y L Y Br Y Br Y L R L R W W L B B B B B B B B B G L G L G L G L B B B B B B B B G Y G Y G Y G Y Gy G Gy G Gy R Gy R Gy B Gy B Gy Gy R L R W R W R G R G B W B W L B L B L W L W L W L W L W L...

Page 651: ...oupler 19 Battery 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 Met...

Page 652: ...ace the fuse s OKp 2 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 181 NGo Clean the battery terminals Recharge or replace the battery OKp 3 Check the main switch Refer to CHE...

Page 653: ...COMMUNICATION CONTROL SYSTEM for YZF R1M 8 172...

Page 654: ...ELECTRICAL COMPONENTS 8 173 EAS20089 ELECTRICAL COMPONENTS...

Page 655: ...unit for YZF R1M 11 CCU Communication Control Unit for YZF R1M 12 EXUP servo motor 13 IMU Inertial Measurement Unit 14 Hydraulic unit assembly 15 Shift switch 16 Stator coil 17 Crankshaft position sen...

Page 656: ...ELECTRICAL COMPONENTS 8 175 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25...

Page 657: ...orber assembly stepping motor for YZF R1M 9 Main fuse 10 Relay unit 11 Starter relay 12 Rear wheel sensor 13 Rear brake light switch 14 Gear position sensor 15 Sidestand switch 16 O2 sensor 17 Oil pre...

Page 658: ...ELECTRICAL COMPONENTS 8 177 EAS30549 CHECKING THE SWITCHES 2 1 3 4 6 5 7 8 9 12 13 14 10 11...

Page 659: ...p 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 switc...

Page 660: ...u 1 range When checking for continuity switch back and forth between the switch positions a few times The switches and their terminal connections are illustrated as in the following example of the mai...

Page 661: ...ri cal system cause the lighting and ignition systems to malfunction and could possibly cause a fire 4 Install Rider seat Passenger seat Refer to GENERAL CHASSIS 1 on page 4 1 EAS31006 REPLACING THE E...

Page 662: ...those of conventional batteries The VRLA Valve Regulated Lead Acid battery should be charged according to the appropriate charging method If the battery is over charged the electrolyte level will dro...

Page 663: ...ip may generate heat in the contact area and a weak clip spring may cause sparks If the battery becomes hot to the touch at any time during the charging process dis connect the battery charger and let...

Page 664: ...oltage should be measured 30 minutes after the engine is stopped b Connect a charger and ammeter to the bat tery and start charging c Make sure that the current is higher than the standard charging cu...

Page 665: ...ion o Replace Starter relay Relay unit starting circuit cut off relay Relay unit fuel pump relay Recommended lubricant Dielectric grease Pocket tester 90890 03112 Analog pocket tester YU 03112 C 1 Pos...

Page 666: ...112 C R W G Y R B R 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 Posi...

Page 667: ...THE IGNITION SPARK GAP 1 Check Ignition spark gap Out of specification o Perform the ignition system troubleshooting starting with step 5 Refer to TROUBLESHOOTING on page 8 6 TIP If the ignition spark...

Page 668: ...TARTER MOTOR OPERATION 1 Check Starter motor operation Does not operate o Perform the electric starting system troubleshooting starting with step 4 Refer to TROUBLESHOOTING on page 8 14 a Connect the...

Page 669: ...r output voltage Out of specification o Replace the rectifi er regulator a Connect the pocket tester DC 20 V to the battery as shown Stator coil resistance 0 112 0 168 W W Digital circuit tester 90890...

Page 670: ...e from the fuel tank 2 Remove Fuel tank Refer to FUEL TANK on page 7 1 3 Remove Fuel pump from the fuel tank 4 Connect Fuel pump coupler Fuel hose 5 Turn the main switch to ON 6 Check Fuel level warni...

Page 671: ...THE COOLANT TEMPERATURE SENSOR 1 Remove Coolant temperature sensor Refer to CYLINDER HEAD on page 5 23 WARNING EWA14130 Handle the coolant temperature sensor with special care Never subject the coolan...

Page 672: ...Measure the throttle position sensor maxi mum resistance 3 Install Throttle position sensor TIP When installing the throttle position sensor ad just its angle properly Refer to ADJUSTING THE THROTTLE...

Page 673: ...ls 1 as shown NOTICE ECA17660 Do not use a 12 V battery to operate the throt tle servo motor TIP Do not use old batteries to operate the throttle servo motor EAS30587 CHECKING THE AIR INDUCTION SYSTEM...

Page 674: ...o AIR FILTER CASE on page 7 4 Air filter case duct Air cut off valve Refer to AIR INDUCTION SYSTEM on page 7 19 2 Check Cylinder identification sensor output voltage Out of specification o Replace a C...

Page 675: ...e air temperature sensor WARNING EWA14110 Handle the intake air temperature sensor with special care Never subject the intake air temperature sensor to strong shocks If the intake air temperature sens...

Page 676: ...e pocket tester u 10 to the in take solenoid terminal as shown c Measure the intake solenoid resistance EAS30598 CHECKING THE STEERING DAMPER SOLENOID 1 Remove Front upper cowling Refer to GENERAL CHA...

Page 677: ...20 V to the right handlebar switch coupler as shown b Turn the main switch to ON c When turning the wheel switch in direction a and b check that the output voltage is within the specified values d Co...

Page 678: ...that the output voltage is within the specified values f When turning the wheel switch in direction b check that the output voltage is within the specified values Output voltage More than 5 V Output...

Page 679: ...MANCE 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 SELF DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE ECU 9...

Page 680: ...d or contaminated fuel Sucked in air Electrical system 1 Battery Discharged battery Faulty battery 2 Fuse s Blown damaged or incorrect fuse Improperly installed fuse 3 Spark plug s Incorrect spark plu...

Page 681: ...returned stopper lever Shift forks Worn shift fork Shift drum Incorrect axial play Worn shift drum groove Transmission Worn gear dog EAS30849 FAULTY CLUTCH Clutch slips 1 Clutch Improperly assembled...

Page 682: ...Incorrect oil level Faulty front fork stepping motor for YZF R1M EAS30611 UNSTABLE HANDLING Handlebar Bent or improperly installed handlebar Steering head components Improperly installed upper bracke...

Page 683: ...own damaged or incorrect fuse Turn signal blinks slowly Faulty meter assembly Faulty main switch Faulty turn signal switch Turn signal remains lit Faulty meter assembly Turn signal blinks quickly Faul...

Page 684: ...ressure sensor hose system malfunction clogged or detached hose 15 Throttle position sensor open or short circuit detected 17 EXUP servo motor open or short circuit detected 18 EXUP servo motor stuck...

Page 685: ...rging voltage is abnormal 50 Faulty ECU memory When this malfunction is detected in the ECU the fault code number might not appear on the meter display 51 Immobilizer unit Code cannot be transmitted b...

Page 686: ...ld Dis plays temperature closer to air temperature When engine is hot Displays current coolant temperature Compare the actually mea sured coolant temperature with the meter display value 07 Rear wheel...

Page 687: ...retract the sides tand with the transmission in gear Sidestand retracted ON Sidestand extended OFF 21 Neutral switch and clutch switch Operate the transmission clutch lever and sidestand Transmission...

Page 688: ...tion code 00 Malfunction code exists Fault code 24 40 42 68 69 If more than one code number is detected the display alternates every two seconds to show all the detected code numbers When all code num...

Page 689: ...intake funnel servo motor 36 Primary injector 1 Actuates the primary injec tor 1 five times at one sec ond intervals Illuminates the engine trou ble and system warning light Check that primary inject...

Page 690: ...system solenoid is actuated five times by listening for the operating sound 49 Intake solenoid Actuates fuel intake sole noid five times at one sec ond intervals Illuminates the engine trou ble and s...

Page 691: ...unication between ABS ECU and SCU 42 Abnormal rear wheel sensor 44 Abnormal SCU EEPROM 46 Abnormal SCU power supply voltage 50 Abnormality inside SCU 66 Steering damper stepping motor manufactured by...

Page 692: ...ction items listed for fault code No 22 198 Atmospheric pressure sensor Brief abnormality detected in atmo spheric pressure sen sor Same as fault code 23 Perform the inspection items listed for fault...

Page 693: ...ble Malfunction in the fuel injection system Dirty or worn spark plug Malfunction in the battery Malfunction in ECU If a fault code is occur ring respond to that first Rarely Code 243 occurs even when...

Page 694: ...EVENT CODE TABLE 9 15...

Page 695: ...el sensor 60 Joint connector 61 Yamaha diagnostic tool cou pler 62 CCU Communication Control Unit OPTION 63 GPS unit OPTION 64 IMU Inertial Measurement Unit 65 Intake solenoid 66 EXUP servo motor 67 C...

Page 696: ...sition sensor 69 O2 sensor 2 right side 70 O2 sensor 1 left side 71 Intake air temperature sensor 72 Atmospheric pressure sensor 73 Intake air pressure sensor 74 Cylinder identification sensor 75 Gear...

Page 697: ...Green Blue G O Green Orange G R Green Red G W Green White G Y Green Yellow Gy B Gray Black Gy G Gray Green Gy R Gray Red Gy Y Gray Yellow L B Blue Black L G Blue Green L R Blue Red L W Blue White L Y...

Page 698: ......

Page 699: ......

Page 700: ......

Page 701: ...W R W R W R W R W R G R G R G R G R G R G R G R W R W R W R W B B B B B B B B L L Br Y Br Y B B R W R W B W B W L Y L Y L Y Br Y Br Y L R L R W W L B B B B B B B B B G L G L G L G L B B B B B B B B G...

Page 702: ...15A 15A 30A 2A B B B B B B B B B B B B B B B B B B B W B B B B B B B B B B B B B B B Gy Gy Gy Gy Gy Gy Gy W Gy Gy Gy Gy W L L B B A B A A B YZF R1 YZF R1F 2015 WIRING DIAGRAM YZF R1 YZF R1F 2015 SCH M...

Page 703: ...y R Gy B Gy B Gy Gy R L R W R W R G R G B W B W L B L B L W L W L W L W L W L W L B L B L B L B B W B W R G O O W W Y Y B B R G R G R G B W B W Gy Gy Gy B Gy B Gy R Gy R W W Gy G Gy G W W W B W B W R...

Page 704: ...B B B B B B B B B B B B B B B B B B B B B B W B B B B B B B B B B B B B B B B B B B B Gy Gy Gy Gy Gy Gy Gy W Gy Gy Gy Gy W L L B B A B C D E A A B C C C C D E YZF R1M YZF R1MF 2015 WIRING DIAGRAM YZF...

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