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Yamaha YZF-R1 2015, Service Manual

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Yamaha YZF-R1 2015 Service Manual Download Page 190

PERIODIC MAINTENANCE

3-16

Refer to “REAR BRAKE” on page 4-55.

EAS30635

CHECKING THE FRONT BRAKE HOSES

The  following  procedure  applies  to  all  of  the
brake hoses and brake hose holders.
1. Check:

•

Brake hose
Cracks/damage/wear 

o

 Replace.

2. Check:

•

Brake hose surface
Partly blackened surface on the brake hose

o

 Replace.

3. Check:

•

Brake hose holder
Loose 

o

 Tighten the holder bolt.

4. Hold the vehicle upright and apply the brake

several times.

5. Check:

•

Brake hose
Brake fluid leakage 

o

 Replace the damaged

hose.
Refer to “FRONT BRAKE” on page 4-43.

EAS30636

CHECKING THE REAR BRAKE HOSE

1. Check:

•

Brake hose
Cracks/damage/wear 

o

 Replace.

2. Check:

•

Brake hose holder
Loose Connection 

o

 Tighten the holder bolt.

3. Hold  the  vehicle  upright  and  apply  the  rear

brake several times.

4. Check:

•

Brake hose
Brake fluid leakage 

o

 Replace the damaged

hose.
Refer to “REAR BRAKE” on page 4-55.

EAS30893

BLEEDING THE HYDRAULIC BRAKE 

SYSTEM (ABS)

WARNING

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: Front brake calipers

• 3rd step: Rear brake caliper

WARNING

EWA16530

Bleed the ABS whenever:

• the system is disassembled.

• a brake hose is loosened, disconnected or

replaced.

• the brake fluid level is very low.

• brake operation is faulty.

TIP

•

Be careful not to spill any brake fluid or allow
the brake fluid reservoir to overflow.

•

When bleeding the ABS, make sure that there
is  always  enough  brake fluid before applying
the brake. Ignoring this precaution could allow
air to enter the ABS, considerably lengthening
the bleeding procedure.

•

If bleeding is difficult, it may be necessary to let
the brake fluid settle for a few hours.

•

Repeat the bleeding procedure when the tiny
bubbles in the hose have disappeared.

1. Bleed:

•

ABS

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼

a. Fill the brake fluid reservoir to the proper level

with the specified brake fluid.

b. Install the diaphragm (brake fluid reservoir).
c. Connect a clear plastic hose “1” tightly to the

bleed screw “2”.

1

1

Summary of Contents for YZF-R1 2015

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

Page 2: ......

Page 3: ...F YZF R1M YZF R1MF SERVICE MANUAL 2015 by Yamaha Motor Co Ltd First edition February 2015 All rights reserved Any reproduction or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited ...

Page 4: ...nificant 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 subject to change without notice EAS30001 IMPORTANT MANUAL INFORMATION Particularly important information is distinguished in this manual by the following notations This is the safety alert symbol I...

Page 5: ...to 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 v o c h c t u l C 2 1 t e k s a g r e v o c h c t u l C 3 2 n i p l e w o D 4 1 p a c r e l l i f l i O 5 FWD FWD 1 2 3 4 5 10 6 Nm 0 6 m kgf 4 3 ft Ibf 3 0 Nm 0 30 m kgf 2 2 ft Ibf 1st T R 2nd Spec...

Page 6: ...rviceable 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 Molybdenum disulfide grease Engine speed Silicone grease Electrical data Apply locking agent LOCTITE Engine oil Replace the part with a new one Silicone fluid G M BF B T R LS M S LT E New S ...

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: ...HE 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 PREPARATION FOR REMOVAL AND DISASSEMBLY 1 48 REPLACEMENT PARTS 1 48 GASKETS OIL SEALS AND O RINGS 1 48 ALUMINUM BOLTS 1 48 LOCK WASHERS PLATES AND COTTER PINS 1 49 BEARINGS AND OIL SEALS 1 49 CIRCLI...

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 seat This information will be needed to order spare parts 1 1 ...

Page 11: ...ease 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 in place of the conventional carburetor system This system can achieve an optimum air fuel ratio required by the engine at all times by using a microprocessor that regulates the fuel injection volume...

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 are input from the throttle position sensor accelerator position sensor coolant temperature sensor atmospheric pressure sensor cylinder identification sensor IMU Inertial Measurement Unit crankshaft p...

Page 13: ...rator 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 sensor 15 Intake air pressure sensor 16 Throttle servo motor 17 Throttle body 18 Atmospheric pressure sensor 19 Air filter case 20 Intake funnel servo motor A Fuel system B Air system C Control system ...

Page 14: ...activates 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 Aims and advantages of using YCC T system Increased engine power By shortening the air intake path higher engine speed is possible o Increased engine power Improved driveability Air intake volume is ...

Page 15: ...YCC 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 upper and lower portion Depending upon operating conditions the funnels can be joined to form a single long funnel or split to create a short funnel This change is performed instantaneously by an el...

Page 16: ...ottle position sensor 2 Throttle servo motor 3 Accelerator position sensor 4 ECU Engine Control Unit 5 Sensor input 6 Neutral switch 7 Crankshaft position sensor 8 Rear wheel sensor 9 Coolant temperature sensor 10 Atmospheric pressure sensor 11 Intake funnel servo motor ...

Page 17: ...ar 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 the engine s rpm range in order to give a perceptual recognition of the engine s current rpm at any given moment Items that can be displayed include the odometer tripmeters intake air temperature cool...

Page 18: ...g 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 engine output Engine control is conducted through the integration and adjustment of the commands from the various controls systems TCS and the other systems explained below to supplement the control ma...

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 motion during starts and acceleration is adopted When a tendency for front wheel lift is detected by the IMU and other sensors for machine attitude en gine output is adjusted to the optimum level to compe...

Page 20: ...onment 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 latitude for damping force adjustment the front suspension adopts separate damping force generating mechanisms for the two sides of the fork with compression stroke damping on the left and rebound stro...

Page 21: ...ous 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 can be recorded via a data logger and with the GPS function the system also enables automatic lap time recording on circuit courses These various forms of data provide objective data to help riders ...

Page 22: ...ver 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 UBS Then the rear braking will switch to rider control TIP If the brakes are operated while the vehicle is traveling at low speeds the UBS will only generate a small brake force UBS operation Brake ...

Page 23: ...ake 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 Second input c Brake fluid is automatically pressurized until the second input exceeds the automatic pres surization d No automatic pressurization ...

Page 24: ...10 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 lever is squeezed However if the brake lever is released then squeezed again the UBS will not operate NOTICE ECA19620 The unified brake system is a system to assist the brake operation However both t...

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 See figure B a b c d e f A Deceleration B Vehicle stopped C Brake lever released then squeezed again after vehicle stops a Input b Automatic pressurization c Input maintained d Pressurization mainta...

Page 26: ...the 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 during brake lever input brake pedal input or UBS control the ABS will operate 3 The hydraulic unit assembly which is the main component of the ABS is centrally located on the vehicle to increase mass ce...

Page 27: ...ing 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 supports the vehicle when cornering 1 2 5 6 7 8 9 10 11 12 3 4 1 1 Hydraulic unit assembly 2 ABS warning light 3 ABS ECU fuse 4 ABS solenoid fuse 5 Front wheel sensor rotor 6 Front wheel sensor 7 Fron...

Page 28: ...ities 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 received from the front and rear wheel sensors In addition the ABS ECU calculates the vehicle chassis speed and the rate of speed reduction based on the wheel speed values The difference between the ...

Page 29: ...deways 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 traction of the tires Even in vehicles equipped with ABS overturning of the vehicle cannot be prevented if it is braked suddenly The ABS functions to prevent the tendency of the wheel to lock by cont...

Page 30: ...ns 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 respective brake force will be the same as during normal braking When the brake lever is squeezed only the front brakes will operate and when the brake pedal is depressed only the rear brake will ope...

Page 31: ...ch 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 13 13 5 6 3 4 15 14 16 17 12 12 9 8 8 7 11 11 1 Front brake master cylinder 2 Rear brake master cylinder 3 Hydraulic unit assembly 4 Rear brake master cylinder pressure sensor 5 Separation solenoid v...

Page 32: ...t 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 occurs turn the main switch to OFF then back to ON The ABS operation is nor mal if the ABS warning light goes off after the vehicle starts off 1 2 1 2 7 3 7 4 5 8 8 6 3 At low speed 4 At high speed 5...

Page 33: ...is 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 opens and closes during ABS operation to adjust the hydraulic pressure input from the brake lever or brake pedal 2 Outlet solenoid valve This valve is closed during normal braking and UBS operation Th...

Page 34: ...ooting 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 Battery 2 AC magneto 3 Rectifier regulator 4 Main fuse 5 ABS motor fuse 6 ABS solenoid fuse 7 Main switch 8 ABS ECU fuse 9 Signaling system fuse 10 Front brake light switch 11 Rear brake light switch...

Page 35: ...raulic 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 brake calipers returns to the front brake master cylinder Rear brake When the ABS is not activated the inlet solenoid valve and separation solenoid valve are open and the outlet solenoid valve and shuttl...

Page 36: ...hamber 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 ABS ECU At this time the ABS ECU controls the opening of the inlet solenoid valve As the inlet solenoid valve opens the brake line from the brake master cylinder opens allowing the brake fluid to be...

Page 37: ...ime 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 opens and closes according to the UBS control signals from the ABS ECU The hydraulic pump draws in the brake fluid from the rear brake master cylinder and automatically pressurizes the rear brake caliper...

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 open and close The brake fluid stored in the buffer chamber is pumped back to the rear brake master cylinder by the hydraulic pump linked to the ABS motor 1 3 13 12 12 6 7 4 16 15 17 18 11 11 10 9 9 a...

Page 39: ...es 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 brake master cylinder 4 Brake pedal 5 Rear brake master cylinder pressure sensor 6 Separation solenoid valve 7 Shuttle solenoid valve 8 ABS motor 9 Hydraulic pump 10 Front brake master cylinder press...

Page 40: ...the 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 be tween yourself and other vehicles 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 c...

Page 41: ...t 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 nature of this technology it is nor mal for a small number of pixels to be inactive STREET MODE TRACK MODE Speedometer The speedometer shows the vehicle s traveling speed For certain markets the dis...

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 While the item is flashing press and hold the wheel switch for one second Transmission gear display This shows which gear the transmission is in This model has 6 gears and a neutral position The neutr...

Page 43: ...tting 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 indicate a malfunction The suspension will remain fixed at its most re cent settings until the SCU is reset To reset the SCU stop the vehicle and turn the key to OFF then ON GPS indicator CCU equipped model...

Page 44: ...erate 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 then be viewable SCU trouble warning icon SCU error code Engine trouble warning icon ECU error code SCU trouble warning YZF R1M The SCU trouble warning icon appears if a prob lem is detected by the su...

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 screen and move back one screen or long push the wheel switch to exit MENU entirely TIP Should vehicle motion be detected the screen will automatically exit MENU and change to the main screen Display Mod...

Page 46: ...nse 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 greater the amount of traction control system intervention is applied There are 9 setting levels available Setting level 1 applies the least amount of overall system in tervention while setting level 9...

Page 47: ...be 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 most strongly reduces wheel lift and setting lev el 1 provides the least amount of system inter vention OFF turns LIF off and LCS will be disabled for the selected YRC mode To customize a YRC mode or...

Page 48: ...ange 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 you want to adjust 3 Select the suspension item Fr COM Fr REB Rr COM Rr REB that you want to adjust TIP To decrease the damping force and soften the suspension increase the setting level To increase...

Page 49: ...in 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 the lap time record data Use the wheel switch to select Display and view the lap record To reset the lap time record data 1 When Lap Time is selected both Display and Reset are displayed 2 Select Re...

Page 50: ...l 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 reset 3 Long push the wheel switch to reset the item TIP Maintenance item names cannot be changed Unit This module allows you to set the fuel consump tion units and for certain markets the display can be...

Page 51: ...l detects lighting conditions and will automatically change the display be tween its day and night settings The photo sen sor also controls a subtle automatic brightness adjustment function within both day and night modes to suit ambient light conditions To set the wallpaper 1 From the MENU screen select Wallpaper 2 Select the mode you want to adjust select DAY for daytime display settings or NIGH...

Page 52: ...heel 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 operational range of the shift indica tor light Shift IND Brightness The shift timing indicator light has six brightness levels Display Description Shift IND Set ting Set the shift indicator pattern to ON Fla...

Page 53: ...e 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 turn the tachometer color dis play mode on or select OFF to turn this func tion off 4 Select Tach IND 1st to set the green zone starting r min 5 Set the starting r min by rotating and then short pushin...

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 the in dicator 3 Select the triangle symbol to exit Display Setting This module allows you to set how the informa tion display items like TRIP 1 ODO C TEMP etc are grouped on the main screen There are...

Page 55: ...ure 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 to set the remaining DISPLAY 1 group items 7 Select the triangle symbol to exit To set the other display groups repeat from step 3 Brightness This function allows you to adjust the general brightness ...

Page 56: ...he 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 switch again to exit and go back to the MENU screen All Reset This function resets everything except the odometer and clock to its factory preset or de fault setting Select YES to reset all items After...

Page 57: ...rect 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 all lubrication jobs Other brands may be similar in function and appearance but inferior in quality EAS30008 GASKETS OIL SEALS AND O RINGS 1 When overhauling the engine replace all gaskets seals and ...

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 check all circlips carefully and replace damaged or distorted circlips Al ways replace piston pin clips after one use When installing a circlip 1 make sure the sharp edged corner 2 is positioned opposit...

Page 59: ...ener 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 fastener s head Screw type 1 Remove Quick fastener TIP To remove the quick fastener loosen the screw with a screwdriver then pull the fastener out 2 Install Quick fastener TIP To install the quick fasten...

Page 60: ...uld 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 the battery leads to the correct battery terminals Reversing the bat tery lead connections could damage the electrical components NOTICE ECA16771 When connecting the battery leads to the battery be su...

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 of silicone grease onto the washer where con tacting the IMU grommet When installing the IMU use only a genuine bolt and washer and tighten the bolt to the specified torque Pay attention not to expos...

Page 62: ...ecks using a waterproof coupler use the specified test harness or a suitable commercially available test har ness Checking the connections Check the leads couplers and connectors for stains rust moisture etc 1 Disconnect Lead Coupler Connector NOTICE ECA16780 When disconnecting a coupler release the coupler lock hold both sections of the cou pler securely and then disconnect the cou pler There are...

Page 63: ...oupler 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 checking the wire harness perform steps 1 to 3 As a quick remedy use a contact revitalizer available at most part stores 5 Check Resistance Pocket tester 90890 03112 Analog pocket tester YU 03112 C Pocke...

Page 64: ...hown 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 sistance 5 40 6 60 k at 0 qC 32 qF 290 390 at 80 qC 176 qF ...

Page 65: ...order 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 Illustration Reference pages Valve spring compressor attachment 90890 01243 Valve spring compressor adapter 26 mm YM 01253 1 5 28 5 34 Ring nut wrench 90890 01268 Spanner wrench YU 01268 4 102 Piston pin pu...

Page 66: ...0890 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 90890 01426 Oil filter wrench YU 38411 3 30 Rod holder 90890 01434 Damper rod holder double ended YM 01434 4 81 4 87 Tool name Tool No Illustration Reference pages YU 33984 ...

Page 67: ...A8703 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 90890 01485 Frame mount insert wrench YM 01485 5 7 Damper rod holder 90890 01504 Damper rod holder YM 01504 4 93 4 95 Tool name Tool No Illustration Reference pages YM A8703 YM A8703 ...

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 rod puller M7x0 75 90890 01576 YM 01576 4 96 4 97 Sheave holder 90890 01701 Primary clutch holder YS 01880 A 5 39 5 40 Tool name Tool No Illustration Reference pages ø42 M7 0 75 ...

Page 69: ...er 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 Pressure gauge YU 03153 7 14 7 15 Carburetor angle driver 2 90890 03173 3 10 Tool name Tool No Illustration Reference pages 90890 03081 YU 33223 YU 44456 ...

Page 70: ...est 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 pressure adapter YU 03210 7 14 Yamaha diagnostic tool 90890 03239 3 12 4 71 4 72 8 53 8 131 8 150 Valve spring compressor 90890 04019 Valve spring compressor YM 04019 5 17 5 20 5 28 5 34 Middle driven sha...

Page 71: ... 04098 Valve guide installer 5 0 mm YM 04098 5 30 Valve guide reamer ø5 90890 04099 Valve guide reamer 5 0 mm YM 04099 5 30 Valve guide remover ø4 5 90890 04116 Valve guide remover 4 5 mm YM 04116 5 30 Valve guide installer ø4 5 90890 04117 Valve guide installer 4 5 mm YM 04117 5 30 Valve guide reamer ø4 5 90890 04118 Valve guide reamer 4 5 mm YM 04118 5 30 Tool name Tool No Illustration Reference...

Page 72: ...90 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 checker 90890 06754 Oppama pet 4000 spark checker YM 34487 8 186 Vacuum pressure pump gauge set 90890 06945 Pressure vacuum tester YB 35956 B 4 22 Tool name Tool No Illustration Reference pages ø18 ...

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: ...HTENING TORQUES 2 14 GENERAL TIGHTENING TORQUE SPECIFICATIONS 2 14 ENGINE TIGHTENING TORQUES 2 15 CHASSIS TIGHTENING TORQUES 2 22 LUBRICATION POINTS AND LUBRICANT TYPES 2 27 ENGINE 2 27 CHASSIS 2 28 LUBRICATION SYSTEM CHART AND DIAGRAMS 2 31 ENGINE OIL LUBRICATION CHART 2 31 LUBRICATION DIAGRAMS 2 33 COOLING SYSTEM DIAGRAMS 2 47 CABLE ROUTING 2 51 ...

Page 76: ...SP FIN FRA GBR GRC HRV HUN IRL ISR ITA NLD NOR POL PRT SVK SVN SWE TUR YZF R1M 2KS2 BEL FRA YZF R1M 2KS6 AUS YZF R1M 2KS7 RUS Dimensions Overall length 2055 mm 80 9 in Overall width 690 mm 27 2 in Overall height 1150 mm 45 3 in Seat height YZF R1 855 mm 33 7 in YZF R1M 860 mm 33 9 in Wheelbase 1405 mm 55 3 in Ground clearance 130 mm 5 12 in Minimum turning radius 3300 mm 129 9 in Weight Curb weigh...

Page 77: ...6 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 oil quantity Quantity disassembled 4 90 L 5 18 US qt 4 31 Imp qt Without oil filter cartridge replacement 3 90 L 4 12 US qt 3 43 Imp qt With oil filter cartridge replacement 4 10 L 4 33 US qt 3 61 Imp...

Page 78: ...shaft 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 3902 in Limit 35 160 mm 1 3842 in Base circle diameter Intake 28 150 28 250 mm 1 1083 1 1122 in Limit 28 100 mm 1 1063 in Lobe height Exhaust 34 220 35 220 mm 1 3472 1 3866 in Limit 34 170 mm 1 3453...

Page 79: ...n 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 force intake 171 40 197 20 N 17 48 20 11 kgf 38 53 44 33 lbf Installed compression spring force exhaust 198 80 228 80 N 20 27 23 33 kgf 44 69 51 43 lbf Spring tilt intake 1 8 mm 0 07 in Spring tilt exhau...

Page 80: ...2 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 color code 0 White 1 Blue 2 Black 3 Brown 4 Green 5 Yel low 6 Pink Clutch Clutch type Wet multiple disc Clutch release method Outer pull rack and pinion pull Clutch lever free play 10 0 15 0 mm 0 39...

Page 81: ...e 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 Throttle position sensor Resistance 1 40 2 60 k Output voltage at idle 0 63 0 73 V Accelerator position sensor Resistance 1 40 2 60 k Output voltage 0 63 0 73 V Idling condition Engine idling speed 1200 140...

Page 82: ...pe 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 front 1 5 mm 0 06 in AUS 1 6 mm 0 06 in EUR ISR RUS Rear tire Type Tubeless Size YZF R1 190 55 ZR17M C 75W YZF R1M 200 55 ZR17M C 78W Manufacturer model YZF R1 BRIDGESTONE BATTLAX RACING STREET RS10R G o...

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 measured on wheel 0 15 mm 0 0059 in Brake pad lining thickness inner 4 5 mm 0 18 in Limit 1 0 mm 0 04 in Brake pad lining thickness outer 4 5 mm 0 18 in Limit 1 0 mm 0 04 in Master cylinder inside diam...

Page 84: ...mum 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 Maximum YZF R1 0 click s out YZF R1M ERS With the adjusting bolt fully turned in Rear suspension Type Swingarm link suspension Spring shock absorber type Coil spring gas oil damper Rear shock absorb...

Page 85: ...ast 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 damping Minimum YZF R1 18 click s out YZF R1M ERS Standard YZF R1 10 click s out YZF R1M ERS Maximum YZF R1 0 click s out YZF R1M ERS With the adjusting screw fully turned in Drive chain Size manufact...

Page 86: ...O 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 output 14 0 V 26 3 A 5000 r min Stator coil resistance 0 112 0 168 W W Rectifier regulator Regulator type Semi conductor short circuit Regulated voltage DC 14 3 14 7 V Rectifier capacity 35 0 A Battery...

Page 87: ...lane 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 position sensor resistance 189 231 Cylinder identification sensor output voltage ON 0 8 V Cylinder identification sensor output voltage OFF 4 8 V Intake air pressure sensor output voltage 3 57 3 71 V 101 3 ...

Page 88: ...15 0 A ABS motor fuse 30 0 A ABS ECU fuse 7 5 A ABS solenoid fuse 15 0 A Terminal fuse 1 2 0 A Backup fuse 7 5 A Electronic throttle valve fuse 7 5 A SCU fuse YZF R1M 7 5 A Spare fuse 15 0 A Spare fuse 10 0 A Spare fuse 7 5 A Spare fuse 2 0 A Spare fuse 30 0 A ...

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 specifications re quire clean dry threads Components should be at room temperature A Distance between flats B Outside thread diameter A nut B bolt General tightening torques Nm m kgf ft lbf 10 mm 6 mm 6 0 ...

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 10 Nm 1 0 m kgf 7 2 ft lbf Camshaft cap bolt M6 20 8 Nm 0 8 m kgf 5 8 ft lbf Camshaft cap bolt new M6 20 10 Nm 1 0 m kgf 7 2 ft lbf Engine mounting adjust bolt M18 2 8 Nm 0 8 m kgf 5 8 ft lbf Engine ...

Page 91: ...lt 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 lbf Fuel rail screw secondary injector M5 4 3 5 Nm 0 35 m kgf 2 5 ft lbf Air filter case cover screw M5 10 2 0 Nm 0 20 m kgf 1 4 ft lbf Fuel rail screw throttle body M5 4 3 5 Nm 0 35 m kgf 2 5 ft lbf ...

Page 92: ...ft 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 cover bolt M6 8 See TIP Oil filter cartridge union bolt M20 1 70 Nm 7 0 m kgf 51 ft lbf Neutral switch M10 1 17 Nm 1 7 m kgf 12 ft lbf Clutch cable holder bolt M6 2 10 Nm 1 0 m kgf 7 2 ft lbf Damper pla...

Page 93: ...Water 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 10 Nm 1 0 m kgf 7 2 ft lbf Front fuel tank bolt M6 2 6 Nm 0 6 m kgf 4 3 ft lbf Rear fuel tank bolt M6 1 4 0 Nm 0 40 m kgf 2 9 ft lbf Fuel tank cap bolt M5 4 4 0 Nm 0 40 m kgf 2 9 ft lbf Intake funne...

Page 94: ...owing 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 tightening sequence as shown in the illustration a Loosen the bolt b Tighten the bolt to 15 Nm 1 5 m kgf 11 ft lbf with a torque wrench c Tighten the bolt further to reach the specified angle 160q TIP Ge...

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 the tightening sequence as shown in the illustration a Loosen the bolt b Tighten the bolt to 3 0 Nm 0 30 m kgf 2 2 ft lbf with a torque wrench c Tighten the bolt further to reach the specified angle 90...

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 m kgf 17 ft lbf 21 40 10 Nm 1 0 m kgf 7 2 ft lbf TIP Connecting rod bolt 1 Tighten the connecting rod bolts to 25 Nm 2 5 m kgf 18 ft lbf 2 Tighten the connecting rod bolts further to reach the speci...

Page 97: ...ror 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 b...

Page 98: ...ZF 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 YZF R1M M32 2 68 Nm 6 8 m kgf 49 ft lbf Front fork cap bolt locknut for YZF R1M M12 2 19 Nm 1 9 m kgf 14 ft lbf Front fork cap bolt for YZF R1M M47 2 20 Nm 2 0 m kgf 14 ft lbf Relay arm nut M10 1 40 N...

Page 99: ...r 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 2 8 ft lbf Side cover bracket bolt M6 5 7 Nm 0 7 m kgf 5 1 ft lbf Front panel bracket screw M5 4 1 8 Nm 0 18 m kgf 1 3 ft lbf Front muffler protector bolt M6 4 7 Nm 0 7 m kgf 5 1 ft lbf Front muffler...

Page 100: ...e 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 2 7 Nm 0 7 m kgf 5 1 ft lbf Fuel tank bracket bolt M6 4 7 Nm 0 7 m kgf 5 1 ft lbf Rear brake hose bracket bolt M6 1 7 Nm 0 7 m kgf 5 1 ft lbf Front fender bolt M6 4 6 Nm 0 6 m kgf 4 3 ft lbf Steering...

Page 101: ...h 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 to the surface of the front fork align a point on the outer edge of the axle with the fork making sure that the axle does not protrude past the fork 3 Tighten the pinch bolt 4 pinch bolt 3 and pinch b...

Page 102: ...journals 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 gallery O ring Water or Crankcase bolt O ring Timing chain cover oil seal outer surface Starter clutch idle gear inner surface and end Starter clutch outer assembly Starter clutch gear Primary driven...

Page 103: ...rings 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 and clutch cable end Engine mounting bolt rear side Collar outer surface Relay arm connecting arm rear shock absorber assembly lower side Pivot shaft Swingarm pivot bearing right side inner surface Swi...

Page 104: ...e 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 and front wheel corner Three Bond No 1215B Between wheel bearing ring nut and rear wheel surface Three Bond No 1215B Lubrication point Lubricant LS LS LS LS LS S S S ...

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: ...r cartridge 6 Main gallery 7 Oil pressure switch 8 Crankshaft 9 Generator rotor 10 Balancer shaft 11 Oil nozzle 12 Sub gallery 13 Timing chain tensioner 14 Intake rocker arm 15 Intake camshaft 16 Exhaust rocker arm 17 Exhaust camshaft 18 Shift fork guide bar upper 19 Main axle 20 Drive axle 21 Mission shower ...

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 12 Shift fork C 13 Drive axle ...

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: ...il cooler 2 Oil delivery pipe 1 3 Oil cooler outlet hose 4 Oil filter cartridge 5 Oil pressure switch 6 Oil delivery pipe 2 7 Oil strainer 8 Oil pump 9 Oil pipe 1 10 Main gallery 11 Relief valve 12 Oil pipe 2 13 Oil pipe 3 14 Oil cooler inlet hose ...

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: ...ead 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 the front fork stepping motor sub lead left over the left handlebar switch lead right handlebar switch lead and main switch lead K Route the front fork stepping motor sub lead right over the throttle...

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

Page 129: ...ositioning 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 breather hose so that it is on the outside of the clutch cable D Point the end of the plastic locking tie out ward E Route the coolant reservoir breather hose between the damper and coolant filler ho...

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

Page 131: ...itch 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 Route the rear brake light switch lead to the outside of the rear wheel sensor lead ...

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 headlight control unit F To intake solenoid G To front left turn signal light H The radiator fan motor couplers may be installed to the electrical components tray in any order Route the radiator fan motor le...

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

Page 135: ...asten 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 the excess end of the plastic locking tie G The oil pressure switch connector sidestand switch coupler shift switch coupler and O2 sensor coupler may be positioned in any order H Place the coupler c...

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

Page 137: ...the 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 turn signal light G Fasten the intake solenoid vacuum hose front left turn signal light lead and auxiliary light lead at the outside of the fuse box 1 with the clamp H Face the clamp on the steering...

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

Page 139: ...d 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 steering damper solenoid sub wire harness F Fasten the intake solenoid vacuum hose front left turn signal light lead and auxiliary light lead at the outside of the fuse box 1 with the clamp G Fasten ...

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

Page 141: ...F 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 above the intake solenoid vacuum hose G To horn H Fasten the leads right handlebar switch lead blue left handlebar switch lead gray main switch lead white sub wire harness for YZF R1M white at the posi...

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

Page 143: ...ear 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 H Connect the rear shock absorber assembly stepping motor leads according to those with identification tape yellow and those without identification tape and then cover the coupler with the coupler c...

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

Page 145: ...e 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 the brake hoses F Route the rear shock absorber assembly stepping motor lead to the inside of the brake hose for YZF R1M G Route the rear shock absorber assembly stepping motor lead to the outside of ...

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

Page 147: ...lead 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 and rear right turn signal light coupler may be posi tioned in any order C Insert the clamp on the rear turn signal light lead into the hole in the tail brake light bracket The installation position of...

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

Page 149: ...wheel 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 clamp I Fasten the brake hose rear brake master cyl inder to hydraulic unit at the metal fitting with large inner diameter side of the clamp J Install the grommet of the rear wheel sensor lead securely t...

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

Page 151: ...er 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 any slack E Fasten the front wheel sensor lead at the white tape with the holder F Install the clamp to the brake hose at the tube section G For YZF R1M H Rear side of the vehicle I Cut off the excess...

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 There is an identifying white paint mark on the upper surface of the pipe of the brake hose front brake master cylinder to the hydraulic unit ...

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 bracket 11 Brake hose joint A 23 mm 0 91 in B 21 2 mm 0 83 in Install the hydraulic unit brake pipe front brake master cylinder to the hydraulic unit and the hydraulic unit brake pipe hydraulic unit...

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

Page 157: ...1 Fuel tank 2 Fuel pump 3 Fuel tank breather hose 4 Fuel tank drain hose 5 Fuel hose fuel tank to fuel rail A Point the end of the clamp outward B Install the fuel tank drain hose with its white paint mark facing outward ...

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

Page 159: ...lamp 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 D Projection on the throttle cable bracket accelerator cable side E 5 mm 0 2 in or less F Protector position 26 mm 1 02 in G Connector color Orange H Point the end of the clamp to the right I Instal...

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

Page 161: ...m 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 apply silicone fluid or water to the air induction system hose B Point the end of the clamp to the left C Point the end of the clamp upward D Insert the air induction system hose until it contacts the re...

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

Page 163: ...oid 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 of the one way valve E Install the clamp at a position within the 13 mm 0 51 in range from the end of the one way valve F Install the surge tank hose with its white paint mark facing upward G Install ...

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

Page 165: ...ion 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 mm 0 08 in or more H Installed length 20 mm 0 79 in I Make sure that the clamp is not installed on the flange of the hose fitting of the thermostat assembly J When installing the thermostat assembly...

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

Page 167: ...t 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 installed on the flange of the hose fitting I Yellow paint mark on the radiator outlet hose J Hose clamp opening K 45q L Point the projections 2 locations on the hose clamp downward M Hose clamp installat...

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 Fasten the sub wire harness to the rear frame with the clamp G Route the GPS unit lead between the pas senger seat cover and the cushion H Route the GPS unit lead as shown in the illustration I Route the...

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

Page 173: ...NG 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 SYSTEM ABS 3 16 CHECKING THE WHEELS 3 17 CHECKING THE TIRES 3 17 CHECKING THE WHEEL BEARINGS 3 19 CHECKING THE SWINGARM OPERATION 3 19 LUBRICATING THE SWINGARM PIVOT 3 19 ADJUSTING THE DRIVE CHAIN SLACK ...

Page 174: ...VEL 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 CHECKING THE FRONT BRAKE LIGHT SWITCH 3 36 ADJUSTING THE REAR BRAKE LIGHT SWITCH 3 36 CHECKING AND LUBRICATING THE CABLES 3 36 CHECKING THE THROTTLE GRIP 3 36 CHECKING AND CHARGING THE BATTERY 3 38 CHE...

Page 175: ...IODIC 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 20000 km 12000 mi 30000 km 18000 mi 40000 km 24000 mi 1 Fuel line Check fuel hoses for cracks or damage 2 Spark plugs Check condition Clean and regap Replace 3 Valves Check valve clearance Adjust Eve...

Page 176: ...ith 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 Brake lever pivot shaft Lubricate with silicone grease 16 Brake pedal pivot shaft Lubricate with lithium soap based grease 17 Clutch lever pivot shaft Lubricate with lithium soap based grease 18 Shift p...

Page 177: ...id 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 coolant leakage Change coolant Every 3 years 27 EXUP system Check operation cable free play and pulley position 28 Front and rear brake switches Check operation 29 Moving parts and cables Lubricate ...

Page 178: ...IS 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 FUEL TANK on page 7 1 2 Check Fuel hose 1 Cracks damage o Replace Loose connection o Connect properly TIP Before removing the fuel hose place a few rags in the area under where it will be removed 3 I...

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 clearance adjustment should be made on a cold engine at room temperature When the valve clearance is to be measured or adjusted the piston must be at top dead center TDC on the compression stroke 1 Remo...

Page 180: ...s 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 d Turn the crankshaft counterclockwise e When piston 3 is at TDC on the compres sion stroke align the TDC mark d on the generator rotor with the generator rotor cover slot b Valve clearance cold Int...

Page 181: ...the 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 it falls into the crankcase 6 Adjust Valve clearance a Pull the rocker arm 1 up and then remove the valve pad 2 TIP Cover the timing chain opening with a rag to prevent the valve pad from falling into...

Page 182: ...and 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 suit able valve pad TIP Refer to the following table for the available valve pads Example Valve pad number A63 Rounded value A65 New valve pad number A65 f Install the new valve pad 3 and then push the...

Page 183: ...minutes 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 CHECKING AND CLEANING THE THROTTLE BODIES on page 7 12 a Connect the Yamaha diagnostic tool Use the diagnostic code number 67 Refer to SELF DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE ECU on page 9 5 b ...

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 synchronization again If a bypass air screw was removed turn the screw in fully and be sure to synchronize the throttle bodies If the throttle body synchronization can not be adjusted using the bypass air ...

Page 185: ...ure 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 page 4 1 EAS30625 CHECKING THE EXHAUST SYSTEM 1 Check Exhaust pipe 1 Exhaust chamber 2 Muffler 3 Cracks damage o Replace Gasket 4 Exhaust gas leaks o Replace 2 Check Tightening torque Exhaust pipe nut ...

Page 186: ...L 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 needs more frequent service if you are riding in unusually wet or dusty areas 4 Install Air filter element Air filter case cover NOTICE ECA20710 Never operate the engine without the air filter elemen...

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 adjusting nut 2 in direction a or b until the specified clutch lever free play is ob tained d Tighten the locknut 1 e Install the right front side cowling Refer to GENERAL CHASSIS 2 on page 4 7 Clutch...

Page 188: ...may 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 point of the brake fluid and could cause vapor lock NOTICE ECA13540 Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately TIP In order to e...

Page 189: ...ust 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 position check that the end of the adjusting bolt c is visible through the hole d c Tighten the locknut 1 to specification WARNING EWA17030 A soft or spongy feeling in the brake pedal can indicate the p...

Page 190: ...WARNING 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 Front brake calipers 3rd step Rear brake caliper WARNING EWA16530 Bleed the ABS whenever the system is disassembled a brake hose is loosened disconnected or replaced the brake fluid level is very low bra...

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 level with the specified brake fluid Refer to CHECKING THE BRAKE FLUID LEVEL on page 3 14 WARNING EWA13110 After bleeding the hydraulic brake system check the brake operation EAS31428 CHECKING THE W...

Page 192: ...ld 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 vehicle Tire air pressure measured on cold tires Loading condition 0 90 kg 0 198 lb Front 250 kPa 2 50 kgf cm 36 psi Rear 290 kPa 2 90 kgf cm 42 psi Loading condition 90 188 kg 198 414 lb Front 250 kPa 2...

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 A drive chain that is too tight will overload the engine and other vital parts and one that is too loose can skip and damage the swing arm or cause an accident Therefore keep the drive chain slack wi...

Page 194: ...DRIVE 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 vehicle is used in dusty areas This vehicle has a drive chain with small rubber O rings between each side plate Steam clean ing high pressure washing certain solvents and the use of a coarse brush can...

Page 195: ...couple 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 head for looseness or binding by turning the front fork all the way in both directions If any binding is felt remove the lower bracket and check the upper and lower bearings Refer to STEERING HEAD on pa...

Page 196: ...ement 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 Refer to ELECTRICAL COMPONENTS on page 8 173 EAS30653 CHECKING THE FRONT FORK 1 Stand the vehicle on a level surface WARNING EWA13120 Securely support the vehicle so that there is no danger of it fal...

Page 197: ...exactly 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 advisable to check the number of clicks of each damping force adjusting mechanism and to modify the specifications as necessary Direction a Spring preload is increased suspen sion is harder Direction b Spr...

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 evenly Uneven adjustment can result in poor han dling and loss of stability NOTICE ECA13590 Never go beyond the maximum or minimum adjustment positions 1 Adjust Spring preload a Turn the main switch to...

Page 199: ...re 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 the right of ERS e The display will change 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...

Page 200: ...ASSEMBLY 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 ECA13590 Never go beyond the maximum or minimum adjustment positions 1 Adjust Spring preload a Loosen the locknut 1 b Adjust the spring preload with the special wrench included in the owner s tool kit...

Page 201: ...ions 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 damping for fast compression damping a Turn the adjusting bolt 1 in direction a or b Spring preload adjusting positions Minimum 77 5 mm 3 05 in Standard 79 0 mm 3 11 in Maximum 85 5 mm 3 37 in Spring pr...

Page 202: ...LOAD 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 maximum or minimum adjustment positions 1 Adjust Spring preload Direction a Compression damping is increased suspension is harder Direction b Compression damping is decreased suspension is softer Compress...

Page 203: ...gine 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 Engine oil also lubricates the clutch and the wrong oil types or additives could cause clutch slippage Therefore do not add any chemical additives or use engine oils with a grade of CD or higher and...

Page 204: ...ed 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 of the new oil filter cartridge with a thin coat of lithium soap based grease NOTICE ECA13390 Make sure the O ring 3 is positioned cor rectly in the groove of the oil filter cartridge d Tighten the ne...

Page 205: ...ngine 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 switch joint with the oil pressure switch 2 WARNING EWA12980 The engine muffler and engine oil are ex tremely hot 5 Install Oil pressure gauge joint 18 mm 1 Oil pressure switch joint bolt 2 6 Install ...

Page 206: ...ation of the coolant If water is used instead of coolant check and if necessary correct the antifreeze concentration of the coolant Use only distilled water However if dis tilled water is not available soft water may be used 3 Start the engine warm it up for several min utes and then turn it off 4 Check Coolant level TIP Before checking the coolant level wait a few minutes until it settles EAS3081...

Page 207: ...ch 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 the detent to allow any re sidual pressure to escape When the hissing sound has stopped press down on the radi ator cap and turn it counterclockwise to re move 2 Remove Water pump drain bolt 1 Copper ...

Page 208: ...is 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 recommended coolant to the maxi mum level mark a 11 Install Coolant reservoir cap 12 Loosen the water pump air bleed bolt 1 to allow any trapped air to escape from the wa ter pump 13 When coolant be...

Page 209: ...tion 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 switch to ON b Loosen the locknut 1 c Turn the adjusting nut 2 in direction c or d until the projection a on the EXUP valve pul ley slightly contacts the stopper b and make sure the EXUP cable black...

Page 210: ...edure 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 soon as possible 1 Check Outer cable Damage o Replace 2 Check Cable operation Rough movement o Lubricate TIP Hold the cable end upright and pour a few drops of lubricant into the cable sheath or use ...

Page 211: ...d 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 Turn the adjusting nut 3 in direction a or b until the specified throttle grip free play is ob tained d Tighten the locknut e Slide the rubber cover to its original position TIP Make sure that the adj...

Page 212: ...nd 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 holes a in the headlight cover and turn the adjusting screw a Turn the adjusting screws 1 in direction b or c Left headlight Right headlight Direction b Headlight beam is raised Direction c Headligh...

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

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

Page 215: ...HIELD 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 FRONT WHEEL 4 27 CHECKING THE FRONT WHEEL 4 27 ASSEMBLING THE FRONT WHEEL 4 28 MAINTENANCE OF THE FRONT WHEEL SENSOR AND SENSOR ROTOR 4 29 ADJUSTING THE FRONT WHEEL STATIC BALANCE 4 30 INSTALLING THE FRO...

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 System 4 65 ABS COMPONENTS CHART 4 67 REMOVING THE HYDRAULIC UNIT ASSEMBLY 4 68 CHECKING THE HYDRAULIC UNIT ASSEMBLY 4 69 CHECKING THE BRAKE PIPES 4 69 INSTALLING THE HYDRAULIC UNIT ASSEMBLY 4 69 HYDRA...

Page 217: ...EMBLY 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 ASSEMBLY 4 110 INSTALLING THE RELAY ARM 4 110 INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY 4 111 SWINGARM 4 112 REMOVING THE SWINGARM 4 113 CHECKING THE SWINGARM 4 113 INSTALLING THE SWINGARM 4 114 CHAIN D...

Page 218: ...ider 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 1 ft Ibf 2 0 Nm 0 20 m kgf 1 4 ft lbf 7 Nm 0 7 m kgf 5 1 ft Ibf 1 2 3 4 5 6 7 8 4 4 4 4 4 4 1 5 Nm 0 15 m kgf 1 1 ft lbf S ...

Page 219: ...ar 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 10 Special washer 1 11 Mudguard assembly 1 12 Rear fender 1 1 2 3 4 5 6 7 9 8 10 11 3 2 2 8 2 12 LT 9 Nm 0 9 m kgf 6 5 ft lbf 7 Nm 0 7 m kgf 5 1 ft lbf 7 Nm 0 7 m kgf 5 1 ft lbf 9 Nm 0 9 m kgf 6 5 ft ...

Page 220: ...he 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 Nm 0 38 m kgf 2 8 ft lbf 4 2 1 FWD FWD ...

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 coupler wire harness 1 Disconnect 11 Protective cap 1 12 Sub wire harness 1 1 1 4 2 3 4 5 6 7 8 9 10 11 12 7 Nm 0 7 m kgf 5 1 ft Ibf 7 Nm 0 7 m kgf 5 1 ft Ibf 7 Nm 0 7 m kgf 5 1 ft Ibf 7 Nm 0 7 m kg...

Page 222: ...oupler 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 EAS31676 CONNECTING TO THE CCU for YZF R1M The CCU Communication Control Unit con nects to the vehicle s CAN Controller Area Net work and has a GPS receiver to enable the recording of vehicle and riding dat...

Page 223: ...maha 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 confusion e Install the passenger seat cover assembly to the original position and then install the bolts Passenger seat cover bolt for YZF R1M 7 Nm 0 7 m kgf 5 1 ft lbf a T R ...

Page 224: ...ng 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 2 3 5 Nm 0 5 m kgf 3 6 ft lbf 5 Nm 0 5 m kgf 3 6 ft lbf ...

Page 225: ...k 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 11 Front side cowling bracket left 2 12 Front side cowling bracket right 2 1 4 5 8 9 12 11 12 11 3 3 3 7 7 7 10 7 9 Nm 0 9 m kgf 6 5 ft lbf 9 Nm 0 9 m kgf 6 5 ft lbf 9 Nm 0 9 m kgf 6 5 ft lbf 9 Nm 0 ...

Page 226: ...4 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 2 1 4 7 6 7 2 1 3 3 5 9 Nm 0 9 m kgf 6 5 ft lbf 9 Nm 0 9 m kgf 6 5 ft lbf 9 Nm 0 9 m kgf 6 5 ft lbf 9 Nm 0 9 m kgf 6 5 ft lbf 3 9 Nm 0 9 m kgf 6 5 ft lbf ...

Page 227: ...move 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 1 2 3 4 5 6 7 1 8 Nm 0 18 m kgf 1 3 ft lbf 3 8 Nm 0 38 m kgf 2 8 ft lbf 7 Nm 0 7 m kgf 5 1 ft Ibf 7 Nm 0 7 m kgf 5 1 ft Ibf 9 Nm 0 9 m kgf 6 5 ft lbf 3 0 Nm 0 30 m kgf 2 2 ft lbf LT FWD FWD ...

Page 228: ...right 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 m kgf 2 8 ft lbf 7 Nm 0 7 m kgf 5 1 ft Ibf 3 8 Nm 0 38 m kgf 2 8 ft lbf 1 8 Nm 0 18 m kgf 1 3 ft lbf 7 Nm 0 7 m kgf 5 1 ft Ibf 2 LT LT 3 5 Nm 0 35 m kgf 2 5 ft lbf 3 5 Nm 0 35 m kgf 2 5 ft lbf 9 Nm ...

Page 229: ...et 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 coupler 1 Disconnect 5 Electrical components tray 1 6 Rectifier regulator 1 7 Wire harness 1 1 2 3 4 5 6 7 7 Nm 0 7 m kgf 5 1 ft Ibf 7 Nm 0 7 m kgf 5 1 ft Ibf ...

Page 230: ...OWLINGS 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 Front side cowling right 1 a Remove the quick fastener screws 2 quick fastener 3 bolt 4 and the collar 5 b Remove the right front side cowling by pulling it forward EAS31382 INSTALLING THE FRONT SID...

Page 231: ...stall 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 panel left 1 Front panel right 2 a Remove the quick fastener 3 and bolt 4 and then pull the panel off EAS31640 INSTALLING THE FRONT PANELS 1 Install Front panel left 1 Front panel right 2 Front side c...

Page 232: ...cover 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 into slots b b Install the side cover bolt 2 and then tighten the bolt to specification 2 Install Front side cowling left Front panel bolt left 3 0 Nm 0 30 m kgf 2 2 ft lbf Front panel bolt right 3 5...

Page 233: ...ng 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 Connect the ECU coupler and then push the lock lever a of the coupler in the direction of the arrow shown 1 b a 1 a ...

Page 234: ...ield 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 4 7 Nm 0 7 m kgf 5 1 ft Ibf 4 0 Nm 0 40 m kgf 2 9 ft lbf 0 4 Nm 0 04 m kgf 0 29 ft lbf 1 2 ...

Page 235: ...ng 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 1 Disconnect 8 Headlight control unit coupler 1 Disconnect 9 Sub wire harness coupler 2 Disconnect For YZF R1M 10 SCU coupler 1 Disconnect For YZF R1M 11 Sub wire harness 1 For YZF R1M 12 Front cowl...

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 cowling assembly stay 1 10 Front cowling 1 1 2 3 4 5 6 7 8 9 10 4 3 Nm 0 43 m kgf 3 1 ft lbf 1 5 Nm 0 15 m kgf 1 1 ft lbf 4 3 Nm 0 43 m kgf 3 1 ft lbf 1 5 Nm 0 15 m kgf 1 1 ft lbf 1 5 Nm 0 15 m kgf 1 1 ft ...

Page 237: ...e 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 solenoid 1 10 Air intake duct valve 1 11 Intake solenoid vacuum hose intake solenoid to air intake duct valve 1 12 Intake solenoid 1 13 Intake solenoid lead sub wire harness 1 1 2 3 4 5 6 7 8 9 10 11 1...

Page 238: ...s 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 windshield assembly 1 TIP Insert projections a on the windshield assem bly into grommets b Insert projections c on the windshield assem bly into holes d Insert slots e in the windshield assembly into proj...

Page 239: ...ke 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 Loose connections o Connect properly Cracks damage o Replace 2 Check Surge tank Cracks damage o Replace 3 Check One way valve Cracks damage faulty o Replace TIP Check that air flows smoothly only in t...

Page 240: ...95 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 the air intake duct valve 2 with the cutouts c in the air intake duct 3 and then turn the air intake duct valve 90q clockwise 1 a 1 a c c 2 3 b b 3 2 ...

Page 241: ...Front 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 kgf 12 ft lbf 6 Nm 0 6 m kgf 4 3 ft Ibf 6 Nm 0 6 m kgf 4 3 ft Ibf LT 21 Nm 2 1 m kgf 15 ft lbf 35 Nm 3 5 m kgf 25 ft lbf 3 8 Nm 0 38 m kgf 2 8 ft lbf 3 8 Nm 0 38 m kgf 2 8 ft lbf 7 Nm 0 7 m kgf 5 1 f...

Page 242: ...nsor 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 kgf 12 ft lbf 6 Nm 0 6 m kgf 4 3 ft Ibf 6 Nm 0 6 m kgf 4 3 ft Ibf LT 21 Nm 2 1 m kgf 15 ft lbf 35 Nm 3 5 m kgf 25 ft lbf 3 8 Nm 0 38 m kgf 2 8 ft lbf 3 8 Nm 0 38 m kgf 2 8 ft lbf 7 Nm 0 7 m kgf 5 1 ft ...

Page 243: ...WHEEL 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 Ibf LT ...

Page 244: ...ensor 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 EAS30146 DISASSEMBLING THE FRONT WHEEL NOTICE ECA21340 Do not drop the wheel sensor rotor or sub ject it to shocks If any solvent gets on the wheel sensor ro tor wipe it off immediately 1 Remove Oil se...

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 made only with the outer race 3 TIP Use a socket 4 that matches the diameter of the wheel bearing outer race b Install the spacer c Install the new wheel bearing left side TIP Place a suitable washer 1 ...

Page 246: ...rewdrivers 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 Replace Iron powder dust o Clean 2 Check Front wheel sensor rotor 1 Cracks damage scratches o Replace the front wheel sensor rotor Iron powder dust solvent o Clean TIP The wheel sensor rotor is installed o...

Page 247: ...s 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 the wheel c Turn the front wheel 90q so that the X1 mark is positioned as shown d Release the front wheel e When the wheel stops put an X2 mark at the bottom of the wheel f Repeat steps c through e ...

Page 248: ...4 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 pattern 2 Apply Sealant TIP Apply Three Bond No 1215B onto the corner of brake disc and wheel 3 Check Front brake discs Refer to CHECKING THE FRONT BRAKE DISCS on page 4 48 4 Lubricate Oil seal lips 5 Ins...

Page 249: ...1M 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 TIP When installing the front wheel sensor check the front wheel sensor lead for twists To route the front wheel sensor lead refer to CABLE ROUTING on page 2 51 9 Measure Distance a between the wheel...

Page 250: ...r 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 front wheel sensor 0 9 1 7 mm 0 035 0 067 in for YZF R1 1 1 1 9 mm 0 043 0 075 in for YZF R1M Thickness gauge 90890 03180 Feeler gauge set YU 26900 9 Front brake caliper bolt 35 Nm 3 5 m kgf 25 ft lbf F...

Page 251: ...ensor 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 wheel 1 11 Brake caliper bracket 1 1 2 3 4 5 6 7 8 9 11 10 16 Nm 1 6 m kgf 12 ft lbf 7 Nm 0 7 m kgf 5 1 ft Ibf 190 Nm 19 m kgf 137 ft lbf 3 4 16 Nm 1 6 m kgf 12 ft lbf ...

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 7 8 9 10 11 12 13 100 Nm 10 m kgf 72 ft lbf 105 Nm 10 5 m kgf 76 ft lbf 8 Nm 0 8 m kgf 5 8 ft Ibf LT LT LT 28 Nm 2 8 m kgf 20 ft lbf 30 Nm 3 0 m kgf 22 ft lbf 5 5 5 LT 5 5 ...

Page 253: ...assembling 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 kgf 58 ft lbf LT LT ...

Page 254: ...Rear 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 removing the rear wheel sensor from the rear brake caliper bracket 3 Loosen Locknuts 1 Adjusting bolts 2 4 Remove Rear wheel axle nut 1 Washer Rear wheel axle 2 Rear wheel Brake caliper bracket NOTICE EC...

Page 255: ...on 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 CHECKING THE FRONT WHEEL on page 4 27 EAS30160 CHECKING THE REAR WHEEL DRIVE HUB 1 Check Rear wheel drive hub 1 Cracks damage o Replace Rear wheel drive hub dampers 2 Damage wear o Replace EAS30161 CHECK...

Page 256: ...tely 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 circumference of the threads of the wheel bearing ring nut 3 Tighten Wheel bearing ring nut 1 TIP Use the wheel bearing ring nut tool 2 to tighten the wheel bearing ring nut by turning it counter clockwise a b ...

Page 257: ...or 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 ROTOR on page 4 29 3 Measure Wheel sensor rotor runout Refer to MAINTENANCE OF THE FRONT WHEEL SENSOR AND SENSOR ROTOR on page 4 29 EAS30164 ADJUSTING THE REAR WHEEL STATIC BALANCE TIP After replaci...

Page 258: ...ection 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 axle nut Rear brake caliper bolts WARNING EWA13500 Make sure the brake hose is routed properly TIP When tightening the wheel axle nut there should be no clearance a between the adjust ing block 1 and a...

Page 259: ...ue 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 part repair or replace the de fective part TIP Measure the distance between the rear wheel sensor rotor and rear wheel sensor in several places in one rotation of the rear wheel Do not turn the rear w...

Page 260: ...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 Reflector 1 For AUS 2CR6 2KS6 RUS 6 Front brake hose holder 1 7 Front brake caliper 1 8 Bleed screw 1 9 Bleed screw 1 Right brake caliper side 3 4 7 8 9 2 1 6 Nm 0 6 m kgf 4 3 ft Ibf 35 Nm 3 5 m kgf 25 ft lbf 5 6 5 Nm 0 5 m kgf 3 6 ft Ibf FWD FWD ...

Page 261: ...voir 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 cylinder holder 1 13 Front brake master cylinder 1 14 Front brake light switch 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 S 6 Nm 0 6 m kgf 4 3 ft Ibf 2 5 Nm 0 25 m kgf 1 8 ft lbf 1 2 Nm 0 12 m kgf 0 87 ft lbf 1 0...

Page 262: ...45 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 ft Ibf BF BF S ...

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 gasket 2 5 Brake hose 1 6 Front brake caliper 1 3 4 5 6 6 Nm 0 6 m kgf 4 3 ft Ibf 32 Nm 3 2 m kgf 23 ft lbf 1 2 35 Nm 3 5 m kgf 25 ft lbf FWD FWD ...

Page 264: ...o 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 Bleed screw 1 9 Bleed screw 1 Right brake caliper side 5 Nm 0 5 m kgf 3 6 ft Ibf 8 9 2 1 5 6 7 3 4 6 7 5 6 7 6 7 BF BF S S FWD FWD ...

Page 265: ...emove 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 brake disc a Place the vehicle on a suitable stand so that the front wheel is elevated b Before measuring the brake disc runout turn the handlebar to the left or right to ensure that the front wheel is ...

Page 266: ...m 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 Remove Brake caliper 5 Install Brake pads Brake pad spring TIP Always install new brake pads and new brake pad spring as a set a Connect a clear plastic hose 1 tightly to the bleed screw 2 Put the other...

Page 267: ...ake 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 applies to both of the brake calipers TIP Before removing the brake caliper drain the brake fluid from the entire brake system 1 Remove Brake hose union bolts 1 Brake hose gaskets 2 Brake hoses 3 TIP Pu...

Page 268: ...the 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 passages brake caliper body Obstruction o Blow out with compressed air WARNING EWA13611 Whenever a brake caliper is disassembled replace the brake caliper piston dust seals and brake caliper piston seals...

Page 269: ...ignated 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 brake fluids may 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 ...

Page 270: ...r 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 Cracks damage o Replace Brake fluid reservoir diaphragm 3 Damage wear o Replace 4 Check Brake hoses Cracks damage wear o Replace EAS30181 ASSEMBLING THE FRONT BRAKE MASTER CYLINDER WARNING EWA13520 Befo...

Page 271: ...riorate 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 brake performance When refilling be careful that water does not enter the brake master cylinder reser voir Water will significantly lower the boil ing point of the brake fluid and could cause vapor lo...

Page 272: ...g 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 Ibf 17 Nm 1 7 m kgf 12 ft lbf 27 Nm 2 7 m kgf 20 ft lbf 2 5 Nm 0 25 m kgf 1 8 ft lbf 1 2 3 4 6 6 7 8 S LT 5 5 FWD FWD ...

Page 273: ...e 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 1 11 Cable guide 1 12 Rear brake master cylinder assembly 1 Do not disassemble the rear brake master cylinder assembly 13 Rear brake light switch coupler 1 Disconnect 14 Rear brake light switch 1 1 ...

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 kgf 8 7 ft lbf 27 Nm 2 7 m kgf 20 ft lbf LT 32 Nm 3 2 m kgf 23 ft lbf FWD FWD ...

Page 275: ...t 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 bolt boot 1 S BF 5 Nm 0 5 m kgf 3 6 ft Ibf 17 Nm 1 7 m kgf 12 ft lbf 2 5 Nm 0 25 m kgf 1 8 ft lbf 1 2 6 7 8 9 10 11 3 5 5 4 4 FWD FWD ...

Page 276: ...eplace 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 Measure the brake disc thickness at a few dif ferent locations Out of specification o Replace Refer to CHECKING THE FRONT BRAKE DISCS on page 4 48 5 Adjust Brake disc runout Refer to CHECKING THE FRONT ...

Page 277: ...liper 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 plug 5 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 6 Check Brake pedal operation Soft ...

Page 278: ...e 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 brake caliper piston Brake caliper cylinder 2 Scratches wear o Replace the brake caliper assembly Brake caliper body 3 Cracks damage o Replace the brake caliper assembly Brake fluid delivery passages br...

Page 279: ...kets 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 1 make sure the brake pipe a passes between the projections b on the brake caliper 2 Remove Rear brake caliper 3 Install Brake pad insulators Brake pad shims onto the brake pads Brake pad spring int...

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 spongy feeling o Bleed the brake sys tem Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM ABS on page 3 16 EAS30193 REMOVING THE REAR BRAKE MASTER CYLINDER 1 Remove Brake hose union bolt 1 Brake hose gas...

Page 281: ...rformance 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 careful that water does not enter the brake fluid reservoir Water will significantly lower the boiling point of the brake fluid and could cause vapor lock NOTICE ECA13540 Brake fluid may damage painted sur...

Page 282: ...EM 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 unit to rear brake caliper 1 6 Hydraulic unit brake pipe front brake master cylinder to hydraulic unit 1 7 Hydraulic unit brake pipe hydraulic unit to front brake calipers 1 1 4 5 6 7 7 Nm 0 7 m kgf 5 1...

Page 283: ...rake 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 hose bracket 1 8 9 10 11 12 13 14 15 16 7 Nm 0 7 m kgf 5 1 ft Ibf 16 Nm 1 6 m kgf 12 ft lbf 7 Nm 0 7 m kgf 5 1 ft Ibf 16 Nm 1 6 m kgf 12 ft lbf 8 Nm 0 8 m kgf 5 8 ft Ibf 10 7 Nm 0 7 m kgf 5 1 ft Ibf...

Page 284: ...nsor 7 Front brake caliper 8 Rear wheel sensor 9 Rear wheel sensor rotor 10 Rear brake caliper 11 Yamaha diagnostic tool coupler 12 ABS motor fuse 13 Hydraulic unit brake pipe hydraulic unit to front brake calipers 14 Hydraulic unit brake pipe front brake master cylinder to hydraulic unit 15 Hydraulic unit brake pipe rear brake master cylinder to hydraulic unit 16 Hydraulic unit brake pipe hydraul...

Page 285: ...removed 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 release the lock NOTICE ECA20080 Do not use a tool to disconnect the ABS ECU coupler 2 Remove Brake hoses Brake pipes TIP Do not operate the brake lever and brake pedal while removing the brake hoses and b...

Page 286: ...es 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 pipe flare nut does not turn easi ly replace the hydraulic unit assembly brake pipes and related parts as a set TIP Do not bend the brake pipe when tightening the brake pipe flare nuts 5 Install Gask...

Page 287: ...t 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 pulsating action generated in the brake lever and brake pedal when the ABS is activated can be tested when the vehicle is stopped The hydraulic unit operation can be tested using the following two methods ...

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 pedal 2 and again in the brake lever 1 in this order TIP ON and OFF on the tool screen indicate when the brakes are being applied and released respectively NOTICE ECA17371 Check that the pulse is felt i...

Page 289: ...battery 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 diagnostic tool coupler 4P 6 Start the Yamaha diagnostic tool and display the diagnosis mode screen 7 Select code No 1 ABS reaction force con firmation 8 Click Action 1 and then operate the brake lever 2 a...

Page 290: ...ed 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 is felt in the brake lever check that the brake hoses and brake pipes are connected correctly to the hydraulic unit assembly If the pulse is hardly felt in either the brake lever or brake pedal check...

Page 291: ...nnect 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 Disconnect 11 Throttle grip 1 12 Front brake light switch connector 2 Disconnect 1 2 3 4 5 6 7 8 9 10 11 12 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 kgf 23 ft lbf 115 Nm 11 5 m kg...

Page 292: ...sconnect 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 kgf 23 ft lbf 115 Nm 11 5 m kgf 83 ft lbf 11 Nm 1 1 m kgf 8 0 ft lbf 3 8 Nm 0 38 m kgf 2 8 ft lbf 3 5 Nm 0 35 m kgf 2 5 ft lbf 32 Nm 3 2 m kgf 23 ft lbf 3 5 Nm 0 35 m kgf 2 5 ft lbf 3 8 Nm 0 38 m kgf 2...

Page 293: ...ar 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 over 2 Install Handlebar left Handlebar right Upper bracket 3 Install Throttle grip 1 Throttle cables Throttle cable housings 2 Grip end TIP Align the projection a on the throttle cable housing with the...

Page 294: ...th 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 handlebar c Wipe off any excess rubber adhesive with a clean rag WARNING EWA13700 Do not touch the handlebar grip until the rub ber adhesive has fully dried TIP There should be 1 3 mm 0 04 0 12 in of clear ...

Page 295: ...lay 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 lever free play 10 0 15 0 mm 0 39 0 59 in a 2 1 ...

Page 296: ...nt 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 bracket pinch bolt 2 Loosen 7 Front fork leg 1 1 2 3 4 5 6 7 6 Nm 0 6 m kgf 4 3 ft Ibf 32 Nm 3 2 m kgf 23 ft lbf 7 Nm 0 7 m kgf 5 1 ft Ibf 26 Nm 2 6 m kgf 19 ft lbf 23 Nm 2 3 m kgf 17 ft lbf ...

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 tube 1 12 Oil seal 1 13 Washer 1 14 Outer tube bushing 1 15 Inner tube bushing 1 16 Damper rod assembly 1 17 Inner tube 1 11 14 8 13 12 10 9 15 16 17 ...

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 procedure applies to both of the front fork legs 1 Turn the spring preload adjusting nut 1 counterclockwise until it stops 2 Remove Cap bolt 1 from the damper rod assembly Guide 2 Spacer 3 Locknut 4 a Pres...

Page 299: ...eal 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 a vise with soft jaws c Separate the outer tube from the inner tube by pulling the outer tube forcefully but careful ly NOTICE ECA19880 Excessive force will damage the bushings Damaged bushings must...

Page 300: ...ar 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 Cracks damage o Replace EAS30209 ASSEMBLING THE FRONT FORK LEGS for YZF R1 The following procedure applies to both of the front fork legs WARNING EWA17090 Note that the amount of the fork oil is differ en...

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 lips with lithium soap based grease Lubricate the outer surface of the inner tube with fork oil Before installing the oil seal cover the top of the front fork leg with a plastic bag to protect the o...

Page 302: ...M10 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 90890 01442 Adjustable fork seal driver 36 46 mm YM 01442 1 3 2 1 Fork seal driver 90890 01442 Adjustable fork seal driver 36 46 mm YM 01442 Rod puller 90890 01437 Universal damping rod bleeding tool se...

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 specification o Correct 15 Install Fork spring 1 Spacer 2 Locknut 3 Damper adjusting rod 2 4 Damper adjusting rod 1 5 Guide 6 Cap bolt 7 along with the O ring a Remove the rod puller and rod puller atta...

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 bolts EAS30210 INSTALLING THE FRONT FORK LEGS for YZF R1 The following procedure applies to both of the front fork legs 1 Install Front fork leg Temporarily tighten the upper and lower bracket pinch bo...

Page 305: ...ck 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 the front brake hose to the right front fork leg with the plastic locking tie 6 Adjust Spring preload Rebound damping Compression damping Lower bracket pinch bolt 23 Nm 2 3 m kgf 17 ft lbf Front fork...

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: ...e 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 stepping motor 1 Loosen 7 Lower bracket pinch bolt 2 Loosen 8 Front fork leg 1 1 2 3 4 6 Nm 0 6 m kgf 4 3 ft Ibf 32 Nm 3 2 m kgf 23 ft lbf 7 Nm 0 7 m kgf 5 1 ft Ibf 26 Nm 2 6 m kgf 19 ft lbf 23 Nm 2 3 m kgf...

Page 308: ...oth 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 1 11 Washer 1 12 Damper rod assembly 1 13 Inner tube 1 9 8 11 10 12 13 19 Nm 1 9 m kgf 14 ft lbf 20 Nm 2 0 m kgf 14 ft lbf 68 Nm 6 8 m kgf 49 ft lbf ...

Page 309: ...inch 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 Loosen the cap bolt 4 using the front fork cap bolt wrench 6 5 Remove Front fork leg EAS31649 DISASSEMBLING THE FRONT FORK LEGS for YZF R1M The following procedure applies to both of the front fork l...

Page 310: ...ewdriver 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 to both of the front fork legs 1 Check Inner tube 1 Outer tube 2 Bends damage scratches o Replace WARNING EWA13650 Do not attempt to straighten a bent inner tube as this may dangerously weaken it Fron...

Page 311: ...pplies 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 legs with the specified amount of the fork oil If both front fork legs are not filled with the specified amount of the fork oil it may cause poor handling and a loss of stability TIP When assembling t...

Page 312: ...tube 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 Washer Oil seal 1 with the fork seal driver 2 7 Install Oil seal clip 1 TIP Adjust the oil seal clip so that it fits into the outer tube s groove Front fork damper rod assembly for YZF R1M 68 Nm 6 8 m k...

Page 313: ...es 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 air bubbles have dispersed TIP Be sure to bleed the front fork leg of any residual air 13 Measure Front fork leg oil level a from the top of the outer tube with the outer tube fully compressed and wit...

Page 314: ...ays 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 tighten the cap bolt to the specified torque is after installing the front fork leg to the vehicle and tightening the lower bracket pinch bolts EAS31652 INSTALLING THE FRONT FORK LEGS for YZF R1M The f...

Page 315: ...Handlebar 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 the illustration 4 Check Cable routing TIP Make sure the brake hose throttle cables clutch Lower bracket pinch bolt 23 Nm 2 3 m kgf 17 ft lbf Front fork cap bolt wrench 42mm 90890 01575 YM 01575 Front ...

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 LEGS for YZF R1M on page 3 24 and ADJUSTING THE DAMP ING FORCE OF THE FRONT FORK LEGS AND REAR SHOCK ABSORBER ASSEM BLY for YZF R1M on page 3 25 1 ...

Page 317: ...Refer 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 brake hose 1 4 Horn bracket 1 5 Lower bracket cover 1 6 Steering damper solenoid coupler 1 Disconnect 7 Steering damper solenoid 1 8 Lock washer 1 9 Upper ring nut 1 LT 1 2 3 4 5 6 7 8 9 11 Nm 1 1 m kgf ...

Page 318: ...ts 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 1 m kgf 8 0 ft lbf 7 Nm 0 7 m kgf 5 1 ft Ibf 52 Nm 5 2 m kgf 38 ft lbf 1st 14 Nm 1 4 m kgf 10 ft lbf 2nd 23 Nm 2 3 m kgf 17 ft lbf LT ...

Page 319: ...ash 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 head pipe 1 with a long rod 2 and hammer b Remove the bearing race 3 from the lower bracket with a floor chisel 4 and hammer c Install a new dust seal and new bearing rac es NOTICE ECA14270 If the bear...

Page 320: ...nut 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 TIP Temporarily tighten the upper and lower bracket pinch bolts EAS30215 CHECKING THE STEERING DAMPER 1 Check Steering damper body Damage oil leaks o Replace the steering damper assembly Steering dam...

Page 321: ...7 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 Connecting arm lower nut Washer Bolt 1 1 1 4 Connecting arm 2 5 Rear shock absorber assembly upper nut Col lar Bolt 1 1 1 6 Relay arm nut Bolt 1 1 7 Collar 1 8 Relay arm 1 9 Rear shock absorber assembly ...

Page 322: ...rts 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 14 40 Nm 4 0 m kgf 29 ft lbf 40 Nm 4 0 m kgf 29 ft lbf 11 14 10 12 13 13 10 40 Nm 4 0 m kgf 29 ft lbf ...

Page 323: ...er 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 Connecting arm lower nut Washer Bolt 1 1 1 5 Connecting arm 2 6 Rear shock absorber assembly upper nut Col lar Bolt 1 1 1 7 Relay arm nut Bolt 1 1 8 Collar 1 9 Relay arm 1 10 Rear shock absorber assembly 1 ...

Page 324: ...R1M 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 4 0 m kgf 29 ft lbf 40 Nm 4 0 m kgf 29 ft lbf 40 Nm 4 0 m kgf 29 ft lbf 12 15 13 14 14 ...

Page 325: ...BSORBER 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 Wear eye protection to prevent eye damage from released gas or metal chips EAS30219 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY 1 Stand the vehicle on a level surface WARNING EWA13120 Securely support...

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 Replace the rear shock absorber assembly Rear shock absorber assembly Gas leaks oil leaks o Replace the rear shock absorber assembly Spring Bushings Damage wear o Replace the bushings Bolts Bends dama...

Page 327: ...1 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 Press in the oil seal so it does not protrude from the end surface of the relay arm Installed depth a 4 0 mm 0 16 in Installed depth a YZF R1 6 0 mm 0 24 in YZF R1M 3 0 mm 0 12 in New 2 1 a New New 2 ...

Page 328: ...en 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 Connecting arm upper nut Relay arm nut 40 Nm 4 0 m kgf 29 ft lbf Rear shock absorber assembly upper nut 40 Nm 4 0 m kgf 29 ft lbf Connecting arm lower nut 40 Nm 4 0 m kgf 29 ft lbf Rear shock absorber ass...

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 lead hook 1 9 Swingarm 1 10 Drive chain 1 11 Dust cover 2 12 Washer 1 13 Bushing 1 14 Bearing 2 105 Nm 10 5m kgf 76 ft lbf 65 Nm 6 5 m kgf 47 ft lbf 1 2 3 4 5 6 7 9 10 12 14 13 7 Nm 0 7 m kgf 5 1 ft Ib...

Page 330: ...l 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 to REMOVING THE DRIVE CHAIN on page 4 117 5 Remove Pivot shaft nut Pivot shaft ring nut 1 TIP Loosen the pivot shaft ring nut with the ring nut wrench 2 6 Remove Pivot shaft 1 TIP Loosen the pivot sh...

Page 331: ...TALLING 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 the character stamp of the oil seals out side Press in the oil seal so it does not protrude from the end surface of the swingarm Recommended cleaning solvent Kerosene Recommended lubricant Lithium s...

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 Left side B Right side Pivot shaft 7 Nm 0 7 m kgf 5 1 ft lbf Damper rod holder 22 mm 90890 01365 Pivot shaft ring nut 65 Nm 6 5 m kgf 47 ft lbf 1 1 a a b 1 2 2 T R 1 2 T R Ring nut wrench 90890 01507 R...

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 kgf 90 ft lbf 1 2 3 4 5 6 6 7 8 10 11 9 12 13 10 Nm 1 0 m kgf 7 2 ft lbf 7 Nm 0 7 m kgf 5 1 ft Ibf E LT LT 28 Nm 2 8 m kgf 20 ft lbf 10 Nm 1 0 m kgf 7 2 ft lbf LT 2 2 ...

Page 334: ...ength 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 formula Drive chain 15 link section length a length b between pin inner sides length c between pin outer sides 2 TIP When measuring a 15 link section of the drive chain make sure that the drive chain ...

Page 335: ...k 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 EAS30231 CHECKING THE DRIVE SPROCKET 1 Check Drive sprocket More than 1 4 tooth a wear o Replace the drive sprocket the rear wheel sprocket and the drive chain as a set Bent teeth o Replace the drive ...

Page 336: ...side 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 rear brake tighten the drive sprocket nut Install washer 1 with the OUT mark a fac ing out Stake the drive sprocket nut 2 at cutouts b in the drive axle 4 Install Shift arm 1 TIP Before installing m...

Page 337: ...s 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 determined by the in stalled shift rod length 1 Measure Installed shift rod length a Incorrect o Adjust 2 Adjust Installed shift rod length a Loosen both locknuts 1 b Turn the shift rod 2 in direction...

Page 338: ...ocknuts 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 0 7 m kgf 5 1 ft lbf b 1 2 1 a T R ...

Page 339: ...INSTALLING 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 5 24 INSTALLING THE CYLINDER HEAD 5 24 VALVES AND VALVE SPRINGS 5 26 REMOVING THE VALVES 5 28 CHECKING THE VALVES AND VALVE GUIDES 5 28 CHECKING THE VALVE SEATS 5 30 CHECKING THE VALVE SPRINGS 5 32 C...

Page 340: ...AFT 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 CRANKCASE 5 67 CHECKING THE CRANKCASE 5 67 ASSEMBLING THE CRANKCASE 5 67 INSTALLING THE CRANKCASE BREATHER COVER 5 69 INSTALLING THE OIL PRESSURE SWITCH 5 69 INSTALLING THE GEAR POSITION SENSOR 5 70 CONNECTI...

Page 341: ...BALANCER ASSEMBLY 5 89 TRANSMISSION 5 90 REMOVING THE TRANSMISSION 5 94 CHECKING THE SHIFT FORKS 5 94 CHECKING THE SHIFT DRUM ASSEMBLY 5 95 CHECKING THE TRANSMISSION 5 95 ASSEMBLING THE MAIN AXLE AND DRIVE AXLE 5 95 INSTALLING THE TRANSMISSION 5 96 ...

Page 342: ...e 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 the reading on the compression gauge stabilizes WARNING EWA17100 To prevent sparking the plug remove all ig nition coil couplers and fuel injector cou plers before cranking the engine TIP The differen...

Page 343: ...7 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 1 Compression pressure with oil applied into the cylinder Reading Diagnosis Higher than without oil Piston ring s wear or damage o Repair Same as without oil Piston valves cylinder head gasket possi...

Page 344: ...age 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 cable 2 1 8 EXUP cable 1 1 9 O2 sensor coupler 2 Disconnect 10 Exhaust pipe 1 1 2 3 4 5 6 7 8 9 10 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 ft lb...

Page 345: ...ect 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 ft lbf 20 Nm 2 0 m kgf 14 ft lbf 6 Nm 0 6 m kgf 4 3 ft Ibf 6 Nm 0 6 m kgf 4 3 ft Ibf 2 0 Nm 0 20 m kgf 1 4 ft lbf 20 Nm 2 0 m kgf 14 ft lbf 8 10 Nm 1 0 m kgf 7 2 ft lbf 14 FWD FWD ...

Page 346: ...sprocket 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 Coolant temperature sensor coupler 1 Disconnect 6 Neutral switch connector 1 Disconnect 7 Stator coil coupler 1 Disconnect 8 Crankshaft position sensor coupler 1 Disconnect 9 Oil pressure switch connec...

Page 347: ...ront 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 adjust bolt 2 FWD FWD 8 Nm 0 8 m kgf 5 8 ft Ibf 70 Nm 7 0 m kgf 51 ft lbf 1 2 3 4 5 6 7 56 Nm 5 6 m kgf 41 ft lbf 56 Nm 5 6 m kgf 41 ft lbf 70 Nm 7 0 m kgf 51 ft lbf 5 6 8 8 ...

Page 348: ...pecification 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 side 9 8 Tighten Engine mounting nut rear lower side 8 9 Tighten Engine mounting nut rear upper side 9 10 Tighten Engine mounting bolt left front side 4 11 Tighten Engine mounting bolt right front si...

Page 349: ...Install 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 Installed depth of gasket b 5 0 mm 0 20 in 1 1 2 3 4 5 6 7 8 9 New 1 a b ...

Page 350: ...iator 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 tighten it to 18 Nm 1 8 m kgf 13 ft lbf 4 Cylinder identification sensor coupler 1 Disconnect 5 Cylinder identification sensor 1 6 Cylinder head cover 1 7 Cylinder head cover gasket 1 8 Cylinder head co...

Page 351: ...l 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 necessary to apply engine oil 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 5 Intake camshaft 1 6 Exhaust camshaft 1 1 2 3 ...

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 pipe 2 1 When removing the oil pipe 2 also remove the water pump inlet pipe Refer to WATER PUMP on page 6 9 72 Nm 7 2 m kgf 52 ft lbf 1 2 3 14 5 4 9 10 7 6 5 LT 8 E LT 6 Nm 0 6 m kgf 4 3 ft Ibf 3 0 N...

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 kgf 7 2 ft lbf 6 Nm 0 6 m kgf 4 3 ft Ibf E 2 3 4 2 3 4 E LT 10 Nm 1 0 m kgf 7 2 ft lbf E LT E LT FWD FWD ...

Page 354: ...r 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 Camshaft cap 1 NOTICE ECA13720 To prevent damage to the cylinder head camshafts or camshaft caps loosen the camshaft cap bolts in stages and in a criss cross pattern working from the outside in 5 Re...

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 35 160 mm 1 3842 in Base circle diameter Intake 28 150 28 250 mm 1 1083 1 1122 in Limit 28 100 mm 1 1063 in Lobe height Exhaust 34 220 35 220 mm 1 3472 1 3866 in Limit 34 170 mm 1 3453 in Base circle d...

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 the camshaft journal to camshaft cap clearance with the Plastigauge d Remove the camshaft caps and then mea sure the width of the Plastigauge 2 5 Measure Camshaft journal diameter a Out of specificat...

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 TIMING CHAIN AND CAMSHAFT SPROCKET 1 Check Timing chain Damage stiffness o Replace the timing chain and camshaft and camshaft sprocket as a set Camshaft journal diameter 25 459 25 472 mm 1 0023 1 00...

Page 358: ...alve 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 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 Push the timing chain tensioner rod in direc t...

Page 359: ...shaft 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 by one and then retighten it to the specific torque and the specific angle TIP Tighten the timing chain cover bolts in the tight ening sequence as shown Installed depth a 4 0 4 5 mm 0 16 0 18 in Roc...

Page 360: ...hould 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 follows 1 camshaft cap mark for cylinder 1 2 camshaft cap mark for cylinder 2 3 camshaft cap mark for cylinder 3 4 camshaft cap mark for cylinder 4 5 Tighten Camshaft cap bolts TIP If the camshaft cap bol...

Page 361: ...d 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 of step b install the rod assem bly in the cylinder block TIP Always use a new gasket d Unlock the timing chain tensioner by turning the crankshaft clockwise and tension the tim ing chain 7 Turn Cran...

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 Three Bond No 1541C onto the mating surfaces of the cylinder head cover and cylin der head cover gasket After installing the cylinder head cover gasket 2 to the cylinder head cover cut off the a secti...

Page 363: ...he 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 kgf 9 4 ft lbf Spark plug new 18 Nm 1 8 m kgf 13 ft lbf T R 1 ...

Page 364: ...fer 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 pipe 1 FWD FWD 1 2 3 4 E 16 Nm 1 6 m kgf 12 ft lbf 12 Nm 1 2 m kgf 8 7 ft lbf 10 Nm 1 0 m kgf 7 2 ft lbf 45 Nm 4 5 m kgf 33 ft lbf 1st 3rd 4th 25 Nm 2 5 m kgf 18 ft lbf 2nd Specified angle 160 15 Nm ...

Page 365: ...ts 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 Place a straightedge 1 and a thickness gauge 2 across the cylinder head b Measure the warpage c If the limit is exceeded resurface the cylinder head as follows d Place a 400 600 grit wet sandpaper on th...

Page 366: ...bolt 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 Exhaust camshaft Intake camshaft Refer to INSTALLING THE CAMSHAFTS on page 5 19 Cylinder head bolt 1 10 1st 10 Nm 1 0 m kgf 7 2 ft lbf 2nd 25 Nm 2 5 m kgf 18 ft lbf 3rd 45 Nm 4 5 m kgf 33 ft lbf 4th 15 Nm ...

Page 367: ...etainer 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 Exhaust valve spring seat 8 The valve spring seat is part of a set together with the valve spring Refer to CHECKING THE VALVE SPRING SEAT on page 5 32 8 Exhaust valve guide 8 9 Intake valve pad 8 10...

Page 368: ...ng 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 seat is part of a set together with the valve spring Refer to CHECKING THE VALVE SPRING SEAT on page 5 32 16 Circlip 8 17 Intake valve guide 8 FWD FWD 11 12 13 14 15 17 M M M M M S 16 ...

Page 369: ...valves 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 valve spring compressor attachment 2 4 Remove Valve spring retainer 1 Valve spring 2 Valve 3 Valve stem seal 4 Valve spring seat 5 TIP Identify the position of each part very carefully so that it can b...

Page 370: ...ve 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 guide inside diameter a Valve stem diameter b Valve stem to valve guide clear ance intake 0 010 0 037 mm 0 0004 0 0015 in Limit 0 080 mm 0 0032 in Valve stem to valve guide clear ance exhaust 0 025 0 052...

Page 371: ... 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 remover ø4 5 90890 04116 Valve guide remover 4 5 mm YM 04116 Valve guide remover ø5 90890 04097 Valve guide remover 5 0 mm YM 04097 Valve guide installer ø4 5 90890 04117 Valve guide installer 4 5 mm Y...

Page 372: ...to 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 stem and the valve guide b Apply molybdenum disulfide oil onto the valve stem c Install the valve into the cylinder head d Turn the valve until the valve face and valve seat are evenly polished then...

Page 373: ...ification 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 VALVE SPRING SEAT NOTICE ECA23020 The valve spring and valve spring seat con stitute a set to maintain high precision If either the valve spring or valve spring seat needs replacing be sure to replace ...

Page 374: ...lves 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 Valve spring 4 Valve spring retainer 5 into the cylinder head TIP Make sure each valve is installed in its original place Install the valve springs with the larger pitch a facing up 4 Install Valve co...

Page 375: ...ve 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 04019 Valve spring compressor YM 04019 Valve spring compressor attach ment 90890 01243 Valve spring compressor adapter 26 mm YM 01253 1 Recommended lubricant Molybdenum disulfide oil ...

Page 376: ...sconnect 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 Woodruff key 1 11 Crankshaft end cover 1 12 Timing mark accessing bolt 1 E LT 6 Nm 0 6 m kgf 4 3 ft Ibf 85 Nm 8 5 m kgf 61 ft lbf 10 Nm 1 0 m kgf 7 2 ft lbf 15 Nm 1 5 m kgf 11 ft lbf 10 Nm 1 0 m kgf 7 2 f...

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 washer with engine oil Install the shaft to the hole of the generator ro tor bolt Lubricate the generator rotor bolt threads and washer mating surfaces with engine oil 2 Tighten Generator rotor bolt 1 TIP...

Page 378: ...cific 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 ROUTING on page 2 51 15mm pin type rotor holding tool 90890 04171 YM 04171 Yamaha bond No 1215 90890 85505 Three bond No 1215 Generator cover bolt 1st 6 Nm 0 6 m kgf 4 3 ft lbf 2nd 3 0 Nm 0 30 m kgf ...

Page 379: ...ter 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 gear 1 FWD FWD 1 2 3 4 5 14 Nm 1 4 m kgf 10 ft lbf E E E LT E ...

Page 380: ...Starter 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 clutch and the starter clutch gear should engage otherwise the starter clutch is faulty and must be replaced c When turning the starter clutch gear counter clockwise B it should turn freely otherwise the...

Page 381: ...the clutch housing assembly 1 with the sheave holder 2 tighten the starter clutch holder bolt 3 Fix the flat surface of the clutch housing as sembly with the sheave holder Sheave holder 90890 01701 Primary clutch holder YS 01880 A 2 3 1 ...

Page 382: ...ASSIS 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 THROTTLE BODIES on page 7 9 1 Starter motor lead 1 Disconnect 2 Starter motor 1 1 2 10 Nm 1 0 m kgf 7 2 ft lbf 3 5 Nm 0 35 m kgf 2 5 ft lbf F W D F W D ...

Page 383: ...er 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 4 5 5 6 4 5 Nm 0 45 m kgf 3 3 ft lbf FWD FWD 7 ...

Page 384: ...tor 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 Replace the brush holder set 5 Measure Brush spring force Out of specification o Replace the brush holder set Mica undercut depth 2 40 mm 0 09 in Digital circuit tester 90890 03174 Model 88 Multimeter ...

Page 385: ...l 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 match mark a on the starter motor yoke with the match mark b on the starter mo tor front cover 1 2 3 a b ...

Page 386: ...NGING 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 on page 5 3 1 Oil pan 1 2 Oil pan gasket 1 3 Oil strainer 1 4 Oil delivery pipe 1 1 5 Oil pipe 1 1 6 Relief valve assembly 1 FWD FWD 1 2 3 4 5 6 LT LT LT 10 Nm 1 0 m kgf 7 2 ft lbf 10 Nm 1 0 m kgf 7...

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 1 0 m kgf 7 2 ft lbf 10 Nm 1 0 m kgf 7 2 ft lbf 10 Nm 1 0 m kgf 7 2 ft lbf 10 Nm 1 0 m kgf 7 2 ft lbf LT LT LT 23 Nm 2 3 m kgf 17 ft lbf 12 6 Nm 0 6 m kgf 4 3 ft Ibf 3 0 Nm 0 30 m kgf 2 2 ft Ibf 1st ...

Page 388: ...ling 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 m kgf 7 2 ft lbf FWD FWD ...

Page 389: ...ime 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 2 Check Oil pump drive chain 1 Damage stiffness o Replace the oil pump drive chain and oil pump drive sprocket as a set 1 1 ...

Page 390: ...the 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 Spring 3 Damage wear o Replace the defective part s Outer rotor to oil pump housing clearance 0 09 0 15 mm 0 0035 0 0059 in Limit 0 22 mm 0 0087 in Oil pump housing to inner and outer rotor clearance 0 06...

Page 391: ...Lubricate 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 installing the inner rotor align the pin 2 in the oil pump shaft with the groove in the inner rotor 3 3 Check Oil pump operation Refer to CHECKING THE OIL PUMP on page 5 49 EAS30343 INSTALLING THE OIL ...

Page 392: ...in 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 kgf 7 2 ft lbf LOCTITE 1 2 2 1 2 T R 1 Oil pipe 1 bolt 10 Nm 1 0 m kgf 7 2 ft lbf LOCTITE Oil strainer bolt 10 Nm 1 0 m kgf 7 2 ft lbf LOCTITE Relief valve assembly bolt 10 Nm 1 0 m kgf 7 2 ft lbf LOCT...

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 0 6 m kgf 4 3 ft lbf 2nd 3 0 Nm 0 30 m kgf 2 2 ft lbf Specified angle 90q Engine oil drain bolt 23 Nm 2 3 m kgf 17 ft lbf New New T R 7 8 2 1 3 4 5 6 9 10 11 12 New T R ...

Page 394: ...move 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 cover gasket 1 4 Dowel pin 2 5 Oil filler cap 1 FWD FWD 1 2 3 4 5 10 6 Nm 0 6 m kgf 4 3 ft Ibf 3 0 Nm 0 30 m kgf 2 2 ft Ibf 1st T R 2nd Specified angle 90 7 Nm 0 7 m kgf 5 1 ft lbf ...

Page 395: ...to 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 3 4 5 6 7 8 9 10 LT LT 10 Nm 1 0 m kgf 7 2 ft lbf E FWD FWD ...

Page 396: ...ate 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 nut 1 13 Conical spring washer 1 14 Clutch boss 1 15 Thrust plate 1 16 Clutch housing assembly 1 17 Bearing 1 18 Washer 1 FWD FWD 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 6 E E E E 10 Nm 1 0 m kgf ...

Page 397: ...4 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 1 TIP While holding the clutch boss 2 with the uni versal clutch holder 3 loosen the clutch boss nut Do not use an impact wrench for removing the clutch boss nut 7 Remove Clutch boss nut Conical spr...

Page 398: ...pecification 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 applying the oil This step should be performed only if the fric tion plates and clutch plates were replaced To measure the total width of the friction plates and clutch plates combine 10 friction plates and...

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 pitting wear o Replace the clutch boss TIP Pitting on the clutch boss splines will cause er ratic clutch operation EAS30354 CHECKING THE PRESSURE PLATE 1 Check Pressure plate 1 1 Pressure plate 2 2 Cracks...

Page 400: ...ng 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 due to the clutch dragging by engine oil when assem bled The pressure plate makes chattering by the clutch dragging and noise occurs between pressure plate cam and clutch boss cam This noise will disa...

Page 401: ...tch 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 friction plate Install the last friction plate 1 offset from the other friction plates 2 making sure to align a projection on the friction plate with the punch mark a on the clutch housing 5 Install Pull ro...

Page 402: ...e 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 to the clutch cover match mark a when there is no free play of the pull lever Make sure that the pull rod teeth and pull lever shaft pinion gear are engaged 9 Adjust Clutch lever free play Refer to ...

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 spring 1 11 Shift shaft spring stopper 1 12 Bearing 1 13 Oil seal 1 14 Bearing 1 FWD FWD 1 2 3 4 5 6 7 8 9 10 11 12 13 14 LT 22 Nm 2 2 m kgf 16 ft lbf E E E E ...

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 and the crankcase boss 5 Mesh the stopper lever with the shift drum seg ment assembly 2 Install Bearing Oil seal Washer 1 Circlip 2 TIP Lubricate the oil seal lips with lithium soap based grease Lubric...

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 Oil pressure switch 1 3 Oil pressure switch joint 1 4 Oil filter cartridge 1 5 Oil filter cartridge union bolt 1 6 Crankcase breather cover 1 1 2 3 4 5 6 10 Nm 1 0 m kgf 7 2 ft lbf 4 0 Nm 0 40 m kgf 2 ...

Page 406: ...mper 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 lbf 17 Nm 1 7 m kgf 12 ft lbf 17 Nm 1 7 m kgf 12 ft lbf 13 Nm 1 3 m kgf 9 4 ft lbf 1 8 Nm 0 18 m kgf 1 3 ft lbf 10 Nm 1 0 m kgf 7 2 ft lbf E LT LT LT LT 7 8 6 Nm 0 6 m kgf 4 3 ft Ibf 3 0 Nm 0 30 m kgf...

Page 407: ...l 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 lbf Specified angle 75 1st 3rd 15 Nm 1 5 m kgf 11 ft lbf 2nd 1 2 3 4 2 2 10 6 2 5 4 24 Nm 2 4 m kgf 17 ft lbf 10 Nm 1 0 m kgf 7 2 ft lbf 10 Nm 1 0 m kgf 7 2 ft lbf 4 2 8 E E E E LT E FWD FWD ...

Page 408: ...earing 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 halves in a mild solvent 2 Thoroughly clean all the gasket surfaces and crankcase mating surfaces 3 Check Crankcase Cracks damage o Replace Oil delivery passages Obstruction o Blow out with compress...

Page 409: ...18 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 u 40 mm 1 57 in bolts 29 30 36 37 39 7 Tighten Crankcase bolts 1 10 Following the tightening order loosen the bolt one by one and then retighten it to the specific torque WARNING EWA16610 If the bol...

Page 410: ...itch 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 the oil pressure switch lead so that it is routed within the range shown in the illustra tion Crankcase bolts 11 20 24 Nm 2 4 m kgf 17 ft lbf Crankcase bolts 21 40 10 Nm 1 0 m kgf 7 2 ft lbf 10 6 8 7...

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 shift drum assembly into the opening b in the gear position sensor 1 Gear position sensor bolt 4 0 Nm 0 40 m kgf 2 9 ft lbf LOCTITE a b 1 1 2 53 New T R a b 1 ...

Page 412: ...fer 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 Oil ring 4 11 Cylinder 1 12 Cylinder gasket 1 13 Dowel pin 2 E 25 Nm 2 5 m kgf 18 ft lbf 1st Specified angle 2nd 180 1 2 3 4 5 6 7 8 9 10 11 12 13 8 E 5 E E E 13 E FWD FWD ...

Page 413: ...and 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 positioned at a or b adjust the piston pin clip ends position by following steps b to c b Install the piston pin clip rotation tool 2 to the piston pin clip TIP When installing the piston pin clip rotation...

Page 414: ...the 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 with the piston pin puller set 3 4 Remove Top ring 2nd ring Oil ring TIP When removing a piston ring open the end gap with your fingers and lift the other side of the ring over the piston crown EAS30747...

Page 415: ...f 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 79 000 79 010 mm 3 1102 3 1106 in Taper limit 0 050 mm 0 0020 in Out of round limit 0 050 mm 0 0020 in C average of D1 D2 D3 D4 D5 D6 Taper front to back maximum difference between D1 D3 D5 Taper side to ...

Page 416: ...lace 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 pin and piston as a set Top ring End gap installed 0 15 0 25 mm 0 0059 0 0098 in Limit 0 50 mm 0 0197 in 2nd ring End gap installed 0 65 0 80 mm 0 0256 0 0315 in Limit 1 15 mm 0 0453 in Oil ring End g...

Page 417: ...stall 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 connecting rod and connecting rod cap d Put a piece of Plastigauge 1 on the crank shaft pin e Assemble the connecting rod halves NOTICE ECA18390 Tighten the connecting rod bolts using the plastic region tigh...

Page 418: ...ap 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 the Plasti gauge is in position c or d h Tighten the connecting rod bolts with a torque wrench i Put a mark 1 on the corner of the connecting rod bolt 2 and the connecting rod cap 3 j Tighten the conn...

Page 419: ...ut 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 the replacement big end bearings sizes P1 P4 refer to the bearings shown in the crankshaft illustration For example if the connecting rod P1 and the crankshaft web P1 numbers are 6 and 2 respectively...

Page 420: ...stall 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 Replace the connecting rod bolts with new ones b After installing the big end bearing assemble the connecting rod and connecting rod cap without installing them onto the crankshaft c Tighten the connecti...

Page 421: ...in 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 Push the piston pin clip insertion tool 3 in the direction as shown in the illustration and place the piston pin clip into the piston pin bore TIP Push in the piston pin clip insertion tool while holdin...

Page 422: ...Lubricate 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 recommended lubricant 9 Install Piston assemblies 1 into the cylinder 2 TIP While holding the piston rings with the hand in Piston pin clip installer tool 90890 04174 YM 04174 3 b 1 4 c Recommended lub...

Page 423: ...orque 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 and then confirm that the torque value is within the range of 40 Nm 4 0 m kgf 29 ft lbf to 85 Nm 8 5 m kgf 61 ft lbf with keeping the torque wrench 175q 185q If torque is out of range replace the con...

Page 424: ...STONS 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 connecting rod bolts a ...

Page 425: ...4 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 Crankshaft journal lower bearing 5 6 Crankshaft journal upper bearing 5 7 Oil nozzle 1 4 8 Oil nozzle 2 5 1 2 2 3 3 4 5 6 7 E E 10 Nm 1 0 m kgf 7 2 ft lbf LT LT E E 3 0 Nm 0 30 m kgf 2 2 ft lbf 8 8 FWD ...

Page 426: ...es 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 Replace the crank shaft journal bearings NOTICE ECA13920 Do not interchange the crankshaft journal bearings To obtain the correct crankshaft journal to crankshaft journal bearing clear ance and prevent ...

Page 427: ...earings 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 journal bear ings 4 Select Crankshaft journal bearings J1 J5 TIP The numbers A stamped into the crankshaft web and the numbers B stamped into the lower crankcase are used to determine the re placemen...

Page 428: ...g 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 portions of the crankcase b Place the upper crankcase upside down on a bench c Install the balancer shaft journal upper bear ings 1 and the balancer shaft into the upper crankcase TIP Align the projec...

Page 429: ...tion 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 crankcase are used to determine the replacement balancer shaft journal bearing siz es J1 J4 refer to the bearings shown in the bal ancer shaft and lower crankcase illustration If J1 J4 are the same use t...

Page 430: ...LY 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 bearings 1 with the notches b in the crankcases Be sure to install each balancer shaft journal bearing in its original place 2 Install Balancer shaft TIP Install by aligning the crankshaft match mark a a...

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 11 O ring 3 12 Oil baffle plate 1 13 Bearing 2 1 2 3 3 4 4 5 6 7 8 9 10 11 12 13 13 LT 10 Nm 1 0 m kgf 7 2 ft lbf 10 Nm 1 0 m kgf 7 2 ft lbf 12 Nm 1 2 m kgf 8 7 ft lbf E E E E LT LT LT LT E FWD FWD ...

Page 432: ...nion 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 13 Bearing housing 1 14 Bearing 1 15 Main axle 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 M M M M E M FWD FWD ...

Page 433: ...er 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 Washer 1 16 Circlip 1 17 6th wheel gear 1 18 Circlip 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 M M M M M M M E E FWD FWD ...

Page 434: ...ling 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 26 M M M M M M M E E FWD FWD ...

Page 435: ...ing 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 shift forks 1 Check Shift fork cam follower 1 Shift fork pawl 2 Bends damage scoring wear o Replace the shift fork 2 Check Shift fork guide bar Roll the shift fork guide bar on a flat surface Bends o...

Page 436: ...nd 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 edges o Replace the defective gear s 4 Check Transmission gear engagement each pinion gear to its respective wheel gear Incorrect o Reassemble the transmission axle assemblies 5 Check Transmission gear m...

Page 437: ...ainer 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 tainer EAS30438 INSTALLING THE TRANSMISSION 1 Install Bearings 1 Oil delivery pipe 3 2 TIP Face the seal side of bearing to the outside 2 Install Main axle assembly 1 Bearing housing 2 b c 1 2 a A 2 1...

Page 438: ...um 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 axle Install the shift drum retainer with its OUT mark c facing outward Make sure that the projection d on the drive axle assembly is inserted into the slot in the crankcase Make sure that the drive ax...

Page 439: ...NG THE OIL COOLER 6 5 INSTALLING THE OIL COOLER 6 5 THERMOSTAT 6 6 REMOVING THE THERMOSTAT ASSEMBLY 6 7 CHECKING THE THERMOSTAT 6 7 ASSEMBLING THE THERMOSTAT ASSEMBLY 6 7 INSTALLING THE THERMOSTAT ASSEMBLY 6 7 WATER PUMP 6 9 DISASSEMBLING THE WATER PUMP 6 11 CHECKING THE WATER PUMP 6 11 ASSEMBLING THE WATER PUMP 6 11 INSTALLING THE WATER PUMP 6 12 ...

Page 440: ...OLANT 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 Disconnect 7 Radiator outlet hose 1 Disconnect 8 Radiator inlet hose 1 Disconnect 9 Radiator 1 10 Radiator fan 2 FWD FWD 10 Nm 1 0 m kgf 7 2 ft lbf 7 Nm 0 7 m kgf 5 1 ft Ibf 8 Nm 0 8 m kgf 5 8 ft Ibf 8 ...

Page 441: ...th 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 tester 1 and radiator cap tester adapter 2 to the radiator cap 3 b Apply the specified pressure for ten seconds and make sure there is no drop in pressure 4 Check Radiator fan Damage o Replace Malfu...

Page 442: ...ied 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 tester adapter 2 to the radiator b Apply 137 3 kPa 1 37 kgf cm 19 9 psi of pressure c Measure the indicated pressure with the gauge 6 Measure Radiator cap opening pressure Below the specified pressure ...

Page 443: ...G 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 page 6 9 4 Oil cooler outlet hose 1 5 Oil cooler 1 FWD FWD 1 3 4 5 10 Nm 1 0 m kgf 7 2 ft lbf LT 10 Nm 1 0 m kgf 7 2 ft lbf LT 10 Nm 1 0 m kgf 7 2 ft lbf LT LT 10 Nm 1 0 m kgf 7 2 ft lbf 2 2 ...

Page 444: ...Install 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 lower 3 4 Tighten Radiator bolt 4 5 Fill Crankcase with the specified amount of the recom mended engine oil Refer to CHANGING THE ENGINE OIL on page 3 30 6 Measure Engine oil pressure Refer to MEASU...

Page 445: ...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 THROTTLE BODIES on page 7 9 Coolant Drain Refer to CHANGING THE COOLANT on page 3 33 1 Cooling system air bleed hose 1 Disconnect 2 Radiator inlet hose 1 3 Thermostat housing cover 1 4 O ring 1 5 Thermostat 1 6 Thermostat housing 1 7 O ring 1 FWD FWD 1 2 3 4 5 6 7 10 Nm 1 0 m kgf 7 2 f...

Page 446: ...e 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 Thermostat housing Thermostat housing cover Cracks damage o Replace EAS30444 ASSEMBLING THE THERMOSTAT ASSEMBLY 1 Install Thermostat housing 1 Thermostat 2 O ring 3 Thermostat housing cover 4 TIP Install the ...

Page 447: ...on 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 Refer to INSTALLING THE RADIATOR on page 6 3 5 Measure Radiator cap opening pressure Below the specified pressure o Replace the radiator cap Refer to CHECKING THE RADIATOR on page 6 2 New ...

Page 448: ...CHASSIS 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 1 Water pump inlet pipe 1 2 Water pump outlet pipe 1 3 Water pump assembly 1 4 Oil cooler stay 3 1 2 4 10 Nm 1 0 m kgf 7 2 ft lbf 10 Nm 1 0 m kgf 7 2 ft lbf 10 Nm 1 0 m kgf 7 2 ft lbf 10 Nm 1 0 m kg...

Page 449: ...ater 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 lbf 10 Nm 1 0 m kgf 7 2 ft lbf FWD ...

Page 450: ...ller 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 Check Bearing Rough movement o Replace 3 Check Water pump inlet pipe Water pump outlet pipe Cracks damage wear o Replace EAS30448 ASSEMBLING THE WATER PUMP 1 Install Oil seal 1 Bearing 2 into the wat...

Page 451: ...cal 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 driven sprocket 2 Fill Cooling system with the specified amount of the recom mended coolant Refer to CHANGING THE COOLANT on page 3 33 3 Check Cooling system Leaks o Repair or replace the faulty part Me...

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: ...L 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 HOSE PRIMARY INJECTOR JOINT SIDE AND SECONDARY INJECTOR JOINT SIDE 7 8 THROTTLE BODIES 7 9 CHECKING THE PRIMARY INJECTORS BEFORE REMOVING 7 12 REMOVING THE PRIMARY INJECTORS 7 12 CHECKING THE PRIMARY ...

Page 454: ...ASSIS 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 Fuel pump 1 8 Fuel pump gasket 1 9 Fuel tank cap 1 1 2 3 4 5 6 7 8 9 6 Nm 0 6 m kgf 4 3 ft Ibf 4 0 Nm 0 40 m kgf 2 9 ft lbf 4 0 Nm 0 40 m kgf 2 9 ft lbf 4 0 Nm 0 40 m kgf 2 9 ft lbf ...

Page 455: ...r 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 is prohibited to wear the cotton work gloves or equivalent coverings 4 Remove Fuel tank TIP Do not set the fuel tank down so that the instal lation surface of the fuel pump is directly under the tan...

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 cover on the fuel hose is in the correct position otherwise the fuel hose will not be properly installed TIP Install the fuel hose onto the fuel pump secure ly and slide the fuel hose connector cover 1...

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 Disconnect 9 Air induction system hose 1 Disconnect 10 Intake funnel servo motor coupler 1 Disconnect 11 Air filter case 1 12 Intake funnel servo motor rod assembly 1 13 Intake funnel assembly 1 14 Intake fun...

Page 458: ...ess 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 INJECTORS WARNING EWA17330 Check the injectors in a well ventilated area free of combustible materials Make sure that there is no smoking or use of electric tools in the vicinity of the injectors Be careful...

Page 459: ...y 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 fuel supply system Deposit o Replace Damage o Replace 2 Check Injector resistance Refer to CHECKING THE FUEL INJEC TORS on page 8 196 EAS31664 CHECKING THE AIR FILTER CASE SEAL 1 Check Air filter case...

Page 460: ...e 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 foreign material to enter or adhere to the injectors fuel rails or O rings Be careful not to twist or pinch the O rings when installing the injectors When installing the injector install it at the same...

Page 461: ...injector 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 the fuel hose will not be properly installed TIP Install the fuel hose securely onto the second ary injector joint until a distinct click is heard To install the fuel hose onto the secondary in jector ...

Page 462: ...4 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 Disconnect 6 Primary injector coupler 4 Disconnect 7 Throttle cable 2 Disconnect 8 Intake solenoid vacuum hose 1 Disconnect 9 Fuel hose throttle body to secondary injector 1 10 Fuel hose fuel tank to...

Page 463: ...rew 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 Nm 2 3 m kgf 17 ft lbf 3 0 Nm 0 30 m kgf 2 2 ft lbf 10 Nm 1 0 m kgf 7 2 ft lbf 16 6 4 5 Nm 0 45 m kgf 3 3 ft lbf FWD FWD ...

Page 464: ...Hose 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 2 5 ft lbf 3 5 Nm 0 35 m kgf 2 5 ft lbf 3 5 Nm 0 35 m kgf 2 5 ft lbf 3 5 Nm 0 35 m kgf 2 5 ft lbf 6 1 2 1 8 8 8 ...

Page 465: ...efer 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 fore cleaning the throttle bodies check the fol lowing items Valve clearance Spark plugs Air filter element Throttle body joints Fuel hoses Air induction system Exhaust system Crankcase breather hose V...

Page 466: ...carbon deposits from the inside of each throttle body in a downward direction from the air filter case side of the throttle body to the engine side NOTICE ECA17590 Do not use a tool such as a wire brush to remove the carbon deposits otherwise the inside of the throttle bodies may be dam aged Do not allow carbon deposits or other for eign materials to enter any of the passages in each throttle body...

Page 467: ...sive 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 tightened to the specified torque 1 Install a new seal onto the end of each injec tor 2 Install the injectors 1 to the fuel rails 2 3 Install the primary injector joint 3 making sure to install them in ...

Page 468: ...tank 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 Residual pres sure in the fuel lines could cause fuel to spurt out when removing the hose NOTICE ECA17490 Be sure to disconnect the fuel hose by hand Do not forcefully disconnect the hose with tools c C...

Page 469: ...ain 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 Press the up button 1 or down button 4 to select ECU in the display and then simulta neously press the up button 1 and center button 2 for 2 seconds or more TIP DIAG 5 appears on the display g Simult...

Page 470: ...a 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 throttle bod ies e Turn the main switch to OFF f 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 ...

Page 471: ...e 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 sensor angle r Turn the throttle grip to the fully open position s Check the meter display value If the meter display value is not 95 109 adjust the accel erator position sensor angle t Repeat steps ...

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

Page 473: ...UCTION 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 valve cover ...

Page 474: ...lter 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 Immobilizer unit coupler 1 3 Air filter case duct 1 4 Atmospheric pressure sensor hose 1 5 Atmospheric pressure sensor 1 6 Damper 1 7 Air cut off valve coupler 1 Disconnect LT 10 Nm 1 0 m kgf 7 2 ft lbf LT 0 ...

Page 475: ...r 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 13 Reed valve assembly 2 14 Reed valve plate 4 LT 10 Nm 1 0 m kgf 7 2 ft lbf LT 0 3 Nm 0 03 m kgf 0 22 ft lbf 9 Nm 0 9 m kgf 6 5 ft lbf 9 12 13 14 12 13 14 10 8 11 FWD FWD ...

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 the coolant temperature is below the specified value the air cut off valve remains open and allows the air to flow into the exhaust pipe until the temperature becomes higher than the specified value 1 ...

Page 477: ...NSTALLING 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 the reed valve assembly so that the open side turns to the exhaust side of the engine 3 Install Reed valve cover A Exhaust side A Reed valve cover bolt 10 Nm 1 0 m kgf 7 2 ft lbf LOCTITE T R ...

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

Page 479: ...NALING 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 49 TROUBLESHOOTING METHOD ECU 8 50 DIAGNOSTIC MODE ECU 8 51 YAMAHA DIAGNOSTIC TOOL 8 52 TROUBLESHOOTING DETAILS ECU 8 54 FUEL PUMP SYSTEM 8 103 CIRCUIT DIAGRAM 8 103 TROUBLESHOOTING 8 107 IMMOBILIZE...

Page 480: ...IRCUIT 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 FUNCTION 8 156 TROUBLESHOOTING DETAILS SCU 8 156 COMMUNICATION CONTROL SYSTEM for YZF R1M 8 169 CIRCUIT DIAGRAM 8 169 TROUBLESHOOTING 8 171 ELECTRICAL COMPONENTS 8 173 CHECKING THE SWITCHES 8 177 CHEC...

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 SENSOR 8 194 CHECKING THE INTAKE SOLENOID 8 195 CHECKING THE STEERING DAMPER SOLENOID 8 195 CHECKING THE FUEL INJECTORS 8 196 CHECKING THE WHEEL SWITCH 8 196 ...

Page 482: ...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 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 Y G Y G Y G Y 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 ...

Page 483: ...lebar switch right 28 Start engine stop switch 29 Relay unit 32 Neutral switch 33 Sidestand switch 37 ECU Engine Control Unit 38 Ignition coil 1 39 Ignition coil 2 40 Ignition coil 3 41 Ignition coil 4 42 Spark plug 60 Joint connector 64 IMU Inertial Measurement Unit 68 Crankshaft position sensor 74 Cylinder identification sensor ...

Page 484: ...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 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 W R W G W G Y Y Y B Y B Y R Y R Y G Y G Br W Br W B B L B L B L W L W G G G B G B G R G R G L G L P P P B P B P W P W P L ...

Page 485: ...lebar switch right 28 Start engine stop switch 29 Relay unit 32 Neutral switch 33 Sidestand switch 37 ECU Engine Control Unit 38 Ignition coil 1 39 Ignition coil 2 40 Ignition coil 3 41 Ignition coil 4 42 Spark plug 60 Joint connector 64 IMU Inertial Measurement Unit 68 Crankshaft position sensor 74 Cylinder identification sensor ...

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 transmission is in neutral the neutral switch is closed and the sidestand is down the sidestand switch circuit is open 10 11 9 1 4 5 7 2 6 3 8 1 Battery 2 Main fuse 3 Main switch 4 Ignition fuse 5 Start...

Page 487: ...s 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 Check the ignition coils Refer to CHECKING THE IGNI TION COILS on page 8 186 NGo Replace the ignition coil s OKp 6 Check the crankshaft position sen sor Refer to CHECKING THE CRANK SHAFT POSITION SENS...

Page 488: ...1 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 Replace the relay unit OKp 13 Check the entire ignition system s wiring Refer to CIRCUIT DIAGRAM on page 8 1 NGo Properly connect or repair the ignition sys tem s wiring OKp Replace the ECU or IMU Refer...

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

Page 490: ...y 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 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 Y G Y G Y G Y 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...

Page 491: ...coupler 19 Battery 20 Engine ground 22 Starter relay 23 Starter motor 25 Handlebar switch right 28 Start engine stop switch 29 Relay unit 30 Starting circuit cut off relay 32 Neutral switch 33 Sidestand switch 37 ECU Engine Control Unit 60 Joint connector 91 Handlebar switch left 97 Clutch switch ...

Page 492: ... 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 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 W R W G W G Y Y Y B Y B Y R Y R Y G Y G Br W Br W B B L B L B L W L W G G G B G B G R G R G L G L P P P B P B P W P W...

Page 493: ...coupler 19 Battery 20 Engine ground 22 Starter relay 23 Starter motor 25 Handlebar switch right 28 Start engine stop switch 29 Relay unit 30 Starting circuit cut off relay 32 Neutral switch 33 Sidestand switch 37 ECU Engine Control Unit 60 Joint connector 91 Handlebar switch left 97 Clutch switch ...

Page 494: ...erating 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 has been met the starting circuit cut off relay is closed and the engine can be started by pressing the side of the start engine stop switch 12 1 11 4 6 6 6 6 a b 8 6 9 7 5 2 3 10 10 a WHEN THE TRANSMI...

Page 495: ...ration 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 to CHECKING THE START ER MOTOR on page 5 43 NGo Repair or replace the starter motor OKp 5 Check the relay unit starting circuit cut off relay Refer to CHECKING THE RE LAYS on page 8 184 NGo Replace ...

Page 496: ...Check 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 right handlebar switch OKp 13 Check the entire starting system s wiring Refer to CIRCUIT DIAGRAM on page 8 9 NGo Properly connect or repair the starting sys tem s wiring OKp Replace the ECU Refer to...

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

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

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 R W R W R W R G R G R W B B B B B Br Y L Y L Y B B B B B B B B B G Y R W R W L R L B L W B W R G R W L R L B L W B W R G W W W W W W B B B B B B B B R R B R W G Y R L B G W B B R G Y L Lg 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 Replace the stator coil assembly OKp 4 Check the rectifier regulator Refer to CHECKING THE RECTI FIER REGULATOR on page 8 188 NGo Replace the rectifier regulator OKp 5 Check the entire charging system s ...

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

Page 504: ...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 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 Y G Y G Y G Y 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 ...

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 Dimmer switch 104 Headlight control unit 105 Headlight high beam 106 Headlight low beam 107 Tail brake light 108 License plate light 109 Auxiliary light ...

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 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 W R W G W G Y Y Y B Y B Y R Y R Y G Y G Br W Br W B B L B L B L W L W G G G B G B G R G R G L G L P P P B P B P W P W P L...

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 Dimmer switch 104 Headlight control unit 105 Headlight high beam 106 Headlight low beam 107 Tail brake light 108 License plate light 109 Auxiliary light ...

Page 508: ...Clean 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 switch Refer to CHECKING THE SWITCHES on page 8 177 NGo The dimmer switch is faulty Replace the left handlebar switch OKp 5 Check the pass LAP switch Refer to CHECKING THE SWITCHES on page 8 177 NGo ...

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 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 Y G Y G Y G Y 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...

Page 511: ...ensor 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 meter 83 Oil pressure and coolant temperature warn ing light 85 Turn signal indicator light 89 Oil pressure switch 90 Rear brake light switch 91 Handlebar switch left 95 Horn switch 96 Horn 98 Turn ...

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 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 W R W G W G Y Y Y B Y B Y R Y R Y G Y G Br W Br W B B L B L B L W L W G G G B G B G R G R G L G L P P P B P B P W P W P L...

Page 513: ...ensor 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 meter 83 Oil pressure and coolant temperature warn ing light 85 Turn signal indicator light 89 Oil pressure switch 90 Rear brake light switch 91 Handlebar switch left 95 Horn switch 96 Horn 98 Turn ...

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 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 entire sig...

Page 515: ...he 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 NGo Properly connect or repair the signaling system s wiring OKp Replace the tail brake light 1 Check the turn signal switch Refer to CHECKING THE SWITCHES on page 8 177 NGo Replace the left handlebar ...

Page 516: ...aling 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 Disconnect the oil pressure switch lead from the oil pressure switch and then check whether the oil pres sure and coolant temperature warn ing light comes on when the lead is connected to the engine ground ...

Page 517: ...erature 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 REPLACING THE ECU En gine Control Unit on page 8 180 1 Check that the engine trouble and system warning light does not come on NGo Repair the faulty parts OKp 2 Check that the QSS is working un der n...

Page 518: ...ace 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 entire signaling system s wiring Refer to CIRCUIT DIAGRAM on page 8 29 NGo Properly connect or repair the signaling system s wiring OKp Replace the ECU Refer to REPLACING THE ECU En gine Control Unit o...

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 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 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...

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 temperature sensor 110 Radiator fan motor right 111 Radiator fan motor left ...

Page 522: ...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 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 W R W G W G Y Y Y B Y B Y R Y R Y G Y G Br W Br W B B L B L B L W L W G G G B G B G R G R G L G L P P P B P B P W P W P L ...

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 temperature sensor 110 Radiator fan motor right 111 Radiator fan motor left ...

Page 524: ...eck 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 NGo Replace the radiator fan motor OKp 5 Check the radiator fan motor relay Refer to CHECKING THE RE LAYS on page 8 184 NGo Replace the radiator fan motor relay OKp 6 Check the coolant temperature s...

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 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 Y G Y G Y G Y 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 ...

Page 527: ...dary 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 wheel sensor 59 Rear wheel sensor 60 Joint connector 61 Yamaha diagnostic tool coupler 64 IMU Inertial Measurement Unit 65 Intake solenoid 66 EXUP servo motor 67 Coolant temperature sensor 68 Cranksha...

Page 528: ...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 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 W R W G W G Y Y Y B Y B Y R Y R Y G Y G Br W Br W B B L B L B L W L W G G G B G B G R G R G L G L P P P B P B P W P W ...

Page 529: ...jector 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 sensor 59 Rear wheel sensor 60 Joint connector 61 Yamaha diagnostic tool coupler 64 IMU Inertial Measurement Unit 65 Intake solenoid 66 EXUP servo motor 67 Coolant temperature sensor 68 Crankshaft posi...

Page 530: ...t 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 following conditions is present and the side of the start engine stop switch is pushed Checking the engine trouble and system warning light The engine trouble and system warning light comes on for around 4...

Page 531: ...rouble 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 cause of the malfunction 2 Check and repair the probable cause of the malfunction 3 Perform the reinstatement action for the fuel injection system Refer to Confirmation of service completion in the ap...

Page 532: ...he 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 displayed on the display simultaneously press the up button 1 and center button 2 for 2 seconds or more 1 Throttle position sensor signal 1 throttle angle 13 Throttle position sensor signal 2 throttl...

Page 533: ...ed 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 If a diagnostic code number does not have a corresponding fault code number the information is shown in DIAGNOSTIC CODE TABLE Refer to SELF DIAGNOSTIC FUNCTION AND DIAG NOSTIC CODE TABLE ECU on page ...

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 and the contents are dis played The freeze frame data FFD is the operation data when a malfunction was detected This data can be used to identify when the malfunction occurred and check the engine cond...

Page 535: ...de 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 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 Turn the main switch to ON Fault code ...

Page 536: ...cking 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 wire harness Crank the engine Fault code number is not 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...

Page 537: ...n 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 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 condition of the pins...

Page 538: ...ay 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 malfunction and check Maintenance job Confirmation of service com pletion 1 Connection of intake air pres sure sensor coupler Check the locking condition of the coupler Disconnect the coupler and check th...

Page 539: ...lt 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 conditions is indicated At sea level Approx 101 kPa 757 6 mmHg 29 8 inHg 1000 m 3300 ft above sea level Approx 90 kPa 675 1 mmHg 26 6 inHg 2000 m 6700 ft above sea level Approx 80 kPa 600 0 mmHg 23 6...

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 number is displayed o Go to item 2 2 Defective intake air pressure sensor Execute the diagnostic mode Code No 03 When engine is stopped Atmospheric pressure at the current altitude and weather condi...

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 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 number is displayed o Go to item 3 3 Wire harness continui...

Page 542: ...G 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 Actuation After the EXUP is fully closed it stops at the opening base position inter mediate position This operation takes approximately 3 seconds during which time the warning light comes on Procedure Ch...

Page 543: ...k 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 No 53 Check the operating sound of the motor Replace if defective 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 5 5 M...

Page 544: ...oupler 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 Defective EXUP servo motor Disconnect the cables and exe cute the diagnostic code Code No 53 Check the operating sound of the motor Replace if defective Turn the main switch to ON Fault code number is...

Page 545: ...curely 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 item 4 4 Wire harness continuity Open or short circuit o Replace the wire harness Between relay unit coupler and ECU coupler blue yellow blue yellow Between relay unit coupler and sidestand switch co...

Page 546: ...TAKE 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 pressure sensor Execute the diagnostic mode Code No 02 When engine is stopped Atmospheric pressure at the current altitude and weather conditions is indicated 0 m above sea level Approx 101 kPa 757 6 mmHg ...

Page 547: ...U 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 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 number is displayed o Go to item 3 3 Wire harness continuity Open or ...

Page 548: ...e 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 sensor 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 cou...

Page 549: ...ute 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 air temperature sensor Replace if defective Refer to CHECKING THE INTAKE AIR TEMPERATURE SENSOR on page 8 194 Turn the main switch to ON Fault code number is not dis played o Service is finished Fault ...

Page 550: ...lue 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 Installed condition of atmo spheric pressure sensor Check for looseness or pinch ing Improperly installed sensor o Reinstall or replace the sensor Turn the main switch to ON Fault code number is not di...

Page 551: ...r 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 replace the wire harness Start the engine warm it up and then race it or execute the diagnostic mode Code No 63 Fault code number is not dis played o Service is finished Fault code number is display...

Page 552: ...shed 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 execute the diagnostic mode Code No 63 Fault code number is not dis played o Service is finished Fault code number is displayed o Go to item 7 7 Malfunction in ECU Replace the ECU Refer to REPLACING...

Page 553: ...er 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 system Able to start engine depending on the number of faulty cylinders Able to drive vehicle depending on the number of faulty cylinders Diagnostic code No 30 Actuation Actuates the cylinder 1 ignitio...

Page 554: ...er 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 COILS on page 8 186 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 6 6 Malfunction i...

Page 555: ...d 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 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 Defective cylinder 2 ignition coil Measure the primary c...

Page 556: ...orange 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 Installed condition of cylinder 3 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 it idle for approximatel...

Page 557: ...t 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 ECU coupler gray green gray 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 ...

Page 558: ...ctor 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 Item Probable cause of malfunction and check Maintenance job Confirmation of service com pletion 1 Identify the malfunctioning pri mary injector Execute the diagnostic mode Code No 36 37 38 39 Identify ...

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 orange black red blue red blue Execute the diagnostic mode Code No 36 37 38 39 No operating sound o Go to item 7 Operating sound o Go to item 8 7 Malfunction in ECU Replace the ECU Refer to REPLACIN...

Page 560: ...he 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 the diagnostic mode Code No 40 41 42 43 No operating sound o Go to item 3 Operating sound o Go to item 8 3 Defective secondary injector Measure the secondary injector resistance Replace if out of spe...

Page 561: ...Inertial 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 Displays the bank angle in increments of 5q 0 5q vehicle is vertical Less than 30q when the sidestand is used Procedure Check that 0 5q is displayed when the vehicle is vertical and that the dis played va...

Page 562: ...itch 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 when the vehicle is vertical and that the displayed value increases as the vehicle contin ues to incline Replace if defective Turn the main switch to ON Fault code number is not dis played o Service is...

Page 563: ...alue 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 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 the diagnostic mode Code No 07 Ro...

Page 564: ...lt 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 h The fault code can also be deleted by activating the diag nostic mode and selecting diag nostic code number 63 Fault code No 42 Item A Rear wheel sensor no normal signals are received from the rea...

Page 565: ...ct 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 or broken terminals and locking condition of the pins Improperly connected o Con nect the coupler securely or replace the wire harness Execute the diagnostic mode Code No 21 When the transmission is...

Page 566: ...n 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 clutch lever released OFF Correct indication o Go to item B 9 Incorrect indication o Go to item B 8 B 8 Malfunction in ECU Replace the ECU Refer to REPLACING THE ECU Engine Control Unit on page 8 180 B...

Page 567: ...n 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 diagnostic mode Code No 21 When the transmission is in neutral ON When the transmission is in gear with the clutch lever released OFF Incorrect indication o Go to item B 2 for the neutral switch When the t...

Page 568: ...e 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 wire harness Between ECU coupler and left handlebar switch coupler black yellow black yellow blue yellow blue yellow Execute the diagnostic mode Code No 21 When the clutch lever is released with the t...

Page 569: ...isplay 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 warning light Procedure Check that the relay unit is actuated five times by listening for the operat ing sound Item Probable cause of malfunction and check Maintenance job Confirmation of service com plet...

Page 570: ...ing 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 Defective relay unit Execute the diagnostic mode Code No 09 Fuel system voltage is below 3 V o Replace the relay unit Start the engine and let it idle for approximately 5 seconds Fault code number i...

Page 571: ...tion 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 the main switch is turned to OFF o Replace the ECU Refer to REPLACING THE ECU Engine Control Unit on page 8 180 Turn the main switch to ON Fault code number is not dis played o Service is finished Fa...

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 No Meter display Procedure Item Probable cause of malfunction and check Maintenance job Confirmation of service com pletion 1 Connection of battery leads Check the battery lead connec tions e g loose ...

Page 573: ...mber 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 No 46 Item Charging voltage is abnormal Fail safe system Able to start engine Able to drive vehicle Diagnostic code No Meter display Procedure Item Probable cause of malfunction and check Maintenance ...

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 position Check with throttle grip in fully open position Item Probable cause of malfunction and check Maintenance job Confirmation of service com pletion 1 Connection of accelerator posi tion sensor cou...

Page 575: ...lt 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 diagnostic mode Code No 14 When the throttle grip is fully closed A value of 12 22 is indicated When the throttle grip is fully open A value of 97 107 is indicated Turn the main switch to ON Fault code n...

Page 576: ...ch 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 throttle servo motor coupler and ECU coupler yellow red yellow red light green red light green red Between ECU coupler and fuse box electronic throttle valve fuse red blue red blue Turn the main switch to...

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 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 nu...

Page 578: ...m 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 connected o Con nect the coupler securely or replace the wire harness Start the engine warm it up and then race it or execute the diagnostic mode Code No 63 Fault code number is not dis played o Servi...

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 ABS warning light is off perform the following procedure Execute the diagnostic mode Code No 16 Rotate the front wheel by hand and check that the indicated value increases Value increases o Go to it...

Page 580: ...lack 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 increases o Go to item 9 and delete the fault code Value does not increase o Go to item 6 6 Defective front wheel sensor Improperly installed sensor o Reinstall or replace the sensor Execute the diagn...

Page 581: ...n 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 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 number is displayed o Go to item 3 3 Wire harness...

Page 582: ...g 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 number is displayed o Go to item 3 3 Wire harness continuity Open or short circuit o Replace the wire harness Between ECU coupler and joint coupler blue white blue white blue black black blue Between...

Page 583: ...ition 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 harness 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 3 3 Wire harness continuity Open or short circuit o Replace the wire...

Page 584: ...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 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 Y G Y G Y G Y 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 ...

Page 585: ...7 Fuel injection system fuse 9 Backup fuse 12 Ignition fuse 18 Joint coupler 19 Battery 20 Engine ground 25 Handlebar switch right 28 Start engine stop switch 29 Relay unit 31 Fuel pump relay 35 Fuel pump 37 ECU Engine Control Unit 60 Joint connector ...

Page 586: ...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 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 W R W G W G Y Y Y B Y B Y R Y R Y G Y G Br W Br W B B L B L B L W L W G G G B G B G R G R G L G L P P P B P B P W P W P ...

Page 587: ...7 Fuel injection system fuse 9 Backup fuse 12 Ignition fuse 18 Joint coupler 19 Battery 20 Engine ground 25 Handlebar switch right 28 Start engine stop switch 29 Relay unit 31 Fuel pump relay 35 Fuel pump 37 ECU Engine Control Unit 60 Joint connector ...

Page 588: ...p 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 NGo Replace the right handlebar switch OKp 5 Check the relay unit fuel pump re lay Refer to CHECKING THE RE LAYS on page 8 184 NGo Replace the relay unit OKp 6 Check the fuel pump Refer to CHECKING ...

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

Page 590: ...y 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 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 Y G Y G Y G Y 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 ...

Page 591: ...tch 4 Main fuse 9 Backup fuse 12 Ignition fuse 18 Joint coupler 19 Battery 20 Engine ground 24 Immobilizer unit 37 ECU Engine Control Unit 60 Joint connector 76 Meter assembly 77 Immobilizer system indicator light 81 Multi function meter ...

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 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 W R W G W G Y Y Y B Y B Y R Y R Y G Y G Br W Br W B B L B L B L W L W G G G B G B G R G R G L G L P P P B P B P W P W P...

Page 593: ...tch 4 Main fuse 9 Backup fuse 12 Ignition fuse 18 Joint coupler 19 Battery 20 Engine ground 24 Immobilizer unit 37 ECU Engine Control Unit 60 Joint connector 76 Meter assembly 77 Immobilizer system indicator light 81 Multi function meter ...

Page 594: ...s 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 all keys are lost the entire immobilizer system must be replaced Therefore it is highly rec ommended to use either standard key for driving and to keep the code re registering key in a safe place Do...

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 flashing but the immobilizer system is still enabled Standby mode Parts to be replaced Key registration requirement Main switch immobilizer unit Standard key ECU Accessory lock and key Main switch Immobi...

Page 596: ...ile 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 indicator light stops flashing 5 seconds after the first standard key is registered the registration mode is deactivated If this occurs the second standard key cannot be registered and steps 2 to 4 nee...

Page 597: ...ain switch OFF c LED on d LED off e Less than 5 0 s f Code re registering key g Remaining standard key h Registration mode A If the immobilizer system indicator light stops flashing 5 seconds after the first standard key is registered the second standard key cannot be registered ...

Page 598: ...e 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 to SELF DIAGNOSIS FAULT CODE INDICATION on page 8 117 Fault code Part Symptom Cause Action 51 IMMOBILIZER UNIT Code cannot be trans mitted between the key and the immobi lizer unit 1 Radio wave interf...

Page 599: ...ch 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 was replaced with a used unit from another vehicle 1 Register the code re registering key 2 Check the wire harness and con nector 3 Replace the main switch immobi lizer unit 4 Replace the ECU Refer ...

Page 600: ...R 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 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 Y G Y G Y G Y 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 ...

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 coupler 64 IMU Inertial Measurement Unit 76 Meter assembly 81 Multi function meter 87 ABS warning light 90 Rear brake light switch 107 Tail brake light A Wire harness C Sub wire harness Yamaha diagn...

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 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 W R W G W G Y Y Y B Y B Y R Y R Y G Y G Br W Br W B B L B L B L W L W G G G B G B G R G R G L G L P P P B P B P W P...

Page 603: ...ebar 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 coupler 64 IMU Inertial Measurement Unit 76 Meter assembly 81 Multi function meter 87 ABS warning light 90 Rear brake light switch 107 Tail brake light A Wire harness C Sub wire harness Yamaha diagnostic ...

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: ...ssembly 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 11 Yamaha diagnostic tool coupler 12 ABS motor fuse ...

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: ...llow 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 customer ABS operation when the ABS warning light comes on 1 The ABS warning light remains on o ABS operates as a normal brake system A malfunction was detected using the ABS self diagnosis function The...

Page 609: ...e 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 TROUBLESHOOTING WARNING EWA17420 Perform the troubleshooting A o B o C in order Be sure to follow the order since a wrong diagnosis could result if the steps are followed in a different order or omitt...

Page 610: ...checks 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 coupler is disconnected The ABS solenoid fuse is blown The wire harness is defective The hydraulic unit assembly is defective The connection with the Yamaha diagnostic tool is defective The battery voltag...

Page 611: ...ht 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 Refer to CHECKING THE SWITCHES on page 8 177 If there is no continuity replace the main switch immobilizer unit 2 Battery Check the condition of the battery Refer to CHECKING AND CHARGING THE BATTER...

Page 612: ...minal 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 Yamaha diagnostic tool is properly connected 2 Wire harness Open circuit in the wire harness between the ABS ECU coupler and the Yamaha diagnostic tool cou pler Check for continuity between blue white ...

Page 613: ...ion 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 displayed in the top part of the window area 1 Recovered The item list of the malfunction detected in the past already recovered are displayed 2 Detected The item list of the malfunction currently occurred a...

Page 614: ...point 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 Foreign material adhered around the front wheel sen sor Incorrect installation of the front wheel Defective sensor rotor or incorrect installation of the rotor Defective front wheel sen sor or incorrec...

Page 615: ...the 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 hydraulic unit assembly 16 Rear wheel sensor open or short circuit Open or short circuit is detected in the rear wheel sensor Defective coupler between the rear wheel sensor and the hydraulic unit assembly O...

Page 616: ...inter 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 installation of the rear wheel sensor Incorrect rotation of the rear wheel Rear brake dragging Defective hydraulic unit assembly 43 45 Front wheel sensor missing pulses Front wheel sensor signal is no...

Page 617: ...ected 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 master cylinder side of hydraulic unit assembly Defective front brake line Defective hydraulic unit assembly 64 Defective rear pressure sen sor Abnormality detected in pressure sensor circuit at rear...

Page 618: ...s 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 maintenance job 1 Foreign material adhered around the front wheel sensor Check the surface of the sensor rotor and wheel sensor for foreign material such as metal particles Clean the sensor rotor and wh...

Page 619: ...d 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 abnormal pulse period Symptom Front wheel sensor signal is not received properly The pulse period is abnormal while the vehicle is traveling Order Item components and probable cause Check or maintenance job...

Page 620: ...eel 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 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 to MAINTENANCE OF THE REAR WHEEL SENSOR AND SENSOR ROTOR on...

Page 621: ...7 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 Replace the wheel sensor or hydraulic unit assembly Refer to FRONT WHEEL on page 4 24 and ABS Anti lock Brake System on page 4 65 Fault code No 16 Item Rear wheel sensor open or short circuit Symptom Open ...

Page 622: ...re 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 malfunctions were found the wheel sensor or hydraulic unit assembly is defective Replace the wheel sensor or hydraulic unit assembly Refer to REAR WHEEL on page 4 34 and ABS Anti lock Brake System on pa...

Page 623: ...eplace 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 motor circuit in the hydraulic unit assembly Order Item components and probable cause Check or maintenance job 1 Blown ABS motor fuse Check the ABS motor fuse If the ABS motor fuse is blown replace the...

Page 624: ...ed 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 looseness distortion and bends Refer to CHECKING THE FRONT WHEEL on page 4 27 2 Incorrect rotation of the front wheel Check that there is no brake disc drag on the front wheel and make sure that it rotates...

Page 625: ...sembly 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 missing pulses Symptom Front wheel sensor signal is not received properly Missing pulses are detected in the signal while the vehicle is traveling Order Item components and probable cause Check or ma...

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 to MAINTENANCE OF THE REAR WHEEL SENSOR AND SENSOR ROTOR on page 4 40 4 Defective rear wheel sensor or incorrect installation of the sensor Check the wheel sensor for damage and the installed conditi...

Page 627: ...pler 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 black 4 Defective charging system Check the charging system Refer to CHARGING SYSTEM on page 8 17 Fault code No 55 Item Hydraulic unit assembly defective ABS ECU Symptom Abnormal data is detected in ...

Page 628: ...k 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 disconnecting or connecting a coupler 4 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 cou...

Page 629: ...r 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 Fault code No 68 Item Defective hydraulic unit assembly defective front pressure sensor Symptom Abnormality detected in pressure sensor circuit at front caliper side of hydraulic unit assembly Order Ite...

Page 630: ...ter 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 meter assembly 4 Defective hydraulic unit assembly Replace the hydraulic unit assembly Refer to ABS Anti lock Brake System on page 4 65 Fault code No 90 Item CAN communication between FI ECU and hydra...

Page 631: ...unit 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 unit assembly Check 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 s...

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 to B 3 DELETING THE FAULT CODES on page 8 150 5 Checking the ABS warning light Refer to CHECKING THE ABS WARNING LIGHT on page 4 73 If the ABS warning light does not turn off the possible causes are f...

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 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 W R W G W G Y Y Y B Y B Y R Y R Y G Y G Br W Br W B B L B L B...

Page 635: ...ble 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 compression damping 118 Rear shock absorber assembly stepping motor rebound damping 119 Steering damper solenoid OPTION A Wire harness C Sub wire harness Yamaha diagnostic tool coupler CCU GPS unit D Sub wir...

Page 636: ...umerical 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 The engine trouble and system warning light come on for 2 0 seconds after the main switch has been turned to ON If the engine trouble and system warning light does not come on under this condition the...

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 52 EAS31014 TROUBLESHOOTING DETAILS SCU This section describes the measures per fault code number displayed on the display Check and ser vice the items or components that are the probable cause of the...

Page 638: ...ce 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 connected 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 ...

Page 639: ...rcuit 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 black 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 warning light comes on o Go to item 3 3 Malfunction in ABS ECU ...

Page 640: ...finished 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 Approximately 12 0 V Procedure Check the displayed SCU power supply voltage Item Probable cause of malfunction and check Maintenance job Confirmation of service com pletion 1 Malfunction in charging system...

Page 641: ...ed 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 warning light comes on o Go to item 2 2 Connection of wire harness SCU coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking cond...

Page 642: ...y 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 OFF and back to ON Fault code number is not dis played o Service is finished Fault code number is displayed o Go to item 5 Fault code No 66 Item Steering damper stepping motor manufactured by Öhlins op...

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 not dis played o Service is finished Fault code number is displayed o Go to item 6 6 Malfunction in SCU Replace the SCU Turn the main switch to OFF and back to ON and check the warning light The warni...

Page 644: ...h 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 assembly Fault code No 93 Item Stepping motor open or short circuit detected Fail safe system Able to start engine Able to drive vehicle Diagnostic code No Meter display Procedure Item Probable cause...

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 stepping motor pink pink pink black pink black pink white pink white pink blue pink blue Between SCU coupler and rear shock absorber assembly stepping motor compression damping white white white bla...

Page 646: ...tor 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 battery 6 white brown white white black brown white white red brown white white green brown white Between rear shock absorber assembly stepping motor rebound damping 5 and power battery 6 yellow brown whi...

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 Replace Refer to FRONT FORK for YZF R1M on page 4 90 REAR SHOCK ABSORBER ASSEMBLY on page 4 104 Turn the main switch to ON Fault code number is not dis played o Service is finished Fault code number ...

Page 648: ...le 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 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 Turn the...

Page 649: ...t 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 Confirmation of service com pletion 1 Zero point adjustment of damp ing force adjustment system was not performed Turn the main switch to OFF and back to ON with the vehi cle stopped Check the ERS icon Th...

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

Page 651: ...coupler 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 Meter assembly 81 Multi function meter A Wire harness C Sub wire harness Yamaha diagnostic tool coupler CCU GPS unit ...

Page 652: ...lace 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 CHECKING THE SWITCHES on page 8 177 NGo Replace the main switch immobilizer unit OKp 4 Check the entire communication control system s wiring Refer to CIRCUIT DIAGRAM on page 8 169 NGo Properly connect ...

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 sensor 18 ECU Engine Control Unit 19 Radiator fan motor 20 Horn 21 Headlight control unit 22 Steering damper solenoid 23 SCU Suspension Control Unit for YZF R1M 24 Front brake light switch 25 Clutch swi...

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: ...sorber 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 pressure switch 18 Cylinder identification sensor 19 Front wheel sensor 20 Radiator fan motor relay 21 Fuse box 3 SCU fuse for YZF R1M 22 Fuse box 2 23 Rectifier regulator 24 Intake air temperature sens...

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: ...op switch 2 Mode switch 3 Pass LAP switch 4 Dimmer switch 5 Horn switch 6 Turn signal switch 7 Hazard switch 8 Clutch switch 9 Sidestand switch 10 Main switch 11 Front brake light switch 12 Shift switch 13 Neutral switch 14 Rear brake light switch ...

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 main switch The switch positions a are shown in the far left column and the switch lead colors b are shown in the top row The continuity i e a closed circuit between switch terminals at a given switch p...

Page 661: ...tri 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 ECU Engine Control Unit 1 Turn the main switch to OFF 2 Replace the ECU Engine Control Unit 3 Clean the throttle bodies and reset the ISC Idle Speed Control learning value Refer to CHECKING AND CLEANI...

Page 662: ...m 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 drop con siderably Therefore take special care when charging the battery NOTICE ECA22960 Use only the specified genuine YAMAHA bat tery Using a different battery may cause the IMU to fail and the engine...

Page 663: ...lip 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 the bat tery cool before reconnecting it Hot batteries can explode As shown in the following illustration the open circuit voltage of a VRLA Valve Reg ulated Lead Acid battery stabilizes about 30 mi...

Page 664: ...Voltage 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 current written on the bat tery TIP If the current is lower than the standard charging current written on the battery this type of battery charger cannot charge the VRLA Valve Regu lated Lead Acid batt...

Page 665: ...tion 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 Positive battery terminal 2 Negative battery terminal 3 Positive tester probe 4 Negative tester probe Relay operation Continuity between 3 and 4 L W R W R W 1 2 3 4 1 Positive battery terminal 2 Negativ...

Page 666: ...3112 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 Positive tester probe sky blue 1 Negative tester probe blue yellow 3 No continuity Positive tester probe blue yellow 3 Negative tester probe sky blue 1 Continuity Positive tester probe sky blue 1 Negativ...

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 gap is within specification the ignition system circuit is operating normally a Remove the ignition coil from the spark plug b Connect the ignition checker 1 as shown Primary coil resistance 0 85 1 ...

Page 668: ...STARTER 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 positive battery terminal 1 and starter motor lead 2 with a jumper lead 3 WARNING EWA13810 A wire that is used as a jumper lead must have at least the same capacity of the bat tery lead otherwise the...

Page 669: ...or 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 03174 Model 88 Multimeter with tachom eter YU A1927 Positive tester probe white 1 Negative tester probe white 2 Positive tester probe white 1 Negative tester probe white 3 Positive tester probe whit...

Page 670: ...se 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 warning light Out of specification o Replace the fuel pump Positive tester probe positive battery terminal 1 Negative tester probe negative battery terminal 2 Horn Coil resistance 1 07 1 11 Digital circui...

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 coolant temperature sen sor to strong shocks If the coolant temper ature sensor is dropped replace it 2 Check Coolant temperature sensor resistance Out of specification o Replace a Connect the pocket teste...

Page 672: ...b 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 POSITION SENSOR on page 7 16 EAS30582 CHECKING THE ACCELERATOR POSITION SENSOR 1 Remove Accelerator position sensor from the throttle body WARNING EWA15960 Handle the accelerator position sensor wit...

Page 673: ...als 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 SOLENOID 1 Check Air induction system solenoid resistance Out of specification o Replace a Remove the air induction system solenoid coupler from the air induction system sole noid b Connect the pock...

Page 674: ...to 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 Connect the test harness speed sensor 3P 1 to the rear speed sensor coupler and wire harness as shown b Connect the pocket tester DC 20 V to the test harness speed sensor 3P Positive tester probe oran...

Page 675: ...ke 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 sensor is dropped replace it 2 Check Intake air temperature sensor resistance Out of specification o Replace Pocket tester 90890 03112 Analog pocket tester YU 03112 C Test harness speed sensor 3P 90890 0...

Page 676: ...he 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 CHASSIS 3 on page 4 17 2 Check Steering damper solenoid resistance Out of specification o Replace the steering damper assembly a Disconnect the steering damper lead coupler from wire harness b Connect t...

Page 677: ...C 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 Connect the pocket tester DC 20 V to the right handlebar switch coupler as shown e When turning the wheel switch in direction Fuel injector Resistance 12 0 20 qC 68 qF Pocket tester 90890 03112 Analog ...

Page 678: ...k 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 voltage Less than 0 5 V 1 2 3 4 a b ...

Page 679: ...RMANCE 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 5 SELF DIAGNOSTIC FUNCTION TABLE 9 5 COMMUNICATION ERROR WITH THE METER 9 6 DIAGNOSTIC CODE SENSOR OPERATION TABLE 9 7 DIAGNOSTIC CODE ACTUATOR OPERATION TABLE 9 10 SELF DIAGNOSTIC FUNCTION AND DIAG...

Page 680: ...ed 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 plug gap Incorrect spark plug heat range Fouled spark plug Worn or damaged electrode Worn or damaged insulator 4 Ignition coil s Cracked or broken ignition coil body Broken or shorted primary or seconda...

Page 681: ...y 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 clutch Improperly adjusted clutch cable Loose or fatigued clutch spring Worn friction plate Worn clutch plate 2 Engine oil Incorrect oil level Incorrect oil viscosity low Deteriorated oil Clutch drag...

Page 682: ...y 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 bracket Improperly installed lower bracket improperly tightened ring nut Bent steering stem Damaged ball bearing or bearing race Front fork leg s Uneven oil levels both front fork legs Unevenly tensioned f...

Page 683: ...lown 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 Faulty meter assembly Horn does not sound Damaged or faulty horn Faulty main switch Faulty horn switch Faulty battery Blown damaged or incorrect fuse Faulty wire harness EAS30848 TROUBLESHOOTING AT THE A...

Page 684: ...pressure 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 EXUP servo motor is detected 19 Sidestand switch a break or disconnection of the blue yellow lead of the ECU is detected 20 Intake air pressure sensor or atmospheric pressure sensor when the main swi...

Page 685: ...arging 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 between the key and the immobilizer unit 52 Immobilizer unit Codes between the key and immobilizer unit do not match 53 Immobilizer unit Codes cannot be transmitted between the ECU and the immobilizer...

Page 686: ...old 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 vehicle speed pulses Rear wheel speed pulse 0 999 Check that the number increases when the rear wheel is rotated The number is cumulative and does not reset each time the wheel is stopped 09 Fuel sy...

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 is in neutral ON Transmission is in gear or the clutch lever released OFF Clutch lever is squeezed with the transmission in gear and when the sides tand is retracted ON Clutch lever is squeezed with ...

Page 688: ...ction 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 numbers are shown the display repeats the same process To reinstate set the start engine stop switch from to 67 ISC Idle Speed Control learning condition display ISC Idle Speed Control learning data era...

Page 689: ...e 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 injector 1 is actuated five times by listening for the operating sound 37 Primary injector 2 Actuates the primary injec tor 2 five times at one sec ond intervals Illuminates the engine trou ble and system ...

Page 690: ...n 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 system warning light Check that intake solenoid is actuated five times by listen ing for the operating sound 50 Relay unit Actuates the relay unit five times at one second inter vals Illuminates the e...

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 Öhlins optional open circuit or short cir cuit detected 89 or Err is displayed Abnormal CAN communication between meter assembly and SCU 93 Stepping motor open or short circuit detected 98 Abnormal IM...

Page 692: ...ection 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 code 23 207 Accelerator posi tion sensor Brief abnormality detected in the accel erator position sensor Same as fault code 59 Perform the inspection items listed for fault code No 59 220 Gear positio...

Page 693: ...able 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 the system is functioning properly 244 Poor start ing inability to start Poor starting inability to start detected No gasoline Malfunction in the fuel injection system Dirty or worn spark plug Malfu...

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

Page 695: ...eel 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 Coolant temperature sensor 68 Crankshaft position 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 senso...

Page 696: ...osition 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 position sensor 76 Meter assembly 77 Immobilizer system indicator light 78 Fuel level warning light 79 Neutral indicator light 80 Shift timing indicator light 81 Multi function meter 82 Stability co...

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 Blue Yellow Lg R Light green Red O B Orange Black O G Orange Green P B Pink Black P L Pink Blue P W Pink White R B Red Black R G Red Green R L Red Blue R W Red White R Y Red Yellow Sb W Sky blue Whit...

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