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Yamaha YZF-R1 2022, Manual

The Yamaha YZF-R1 2022 is a high-performance super sport motorcycle built for adrenaline seekers. Unlock the full potential of this beast with the comprehensive owner's manual, available for free download on our website. Brush up on its features, maintenance tips, and optimal performance settings at manualshive.com.

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1

 ................................................................................. 1

2  Kit Parts ........................................................................................................ 2

2-1  Installing Electrical Parts ..............................................................................2

1.

ECU Set (B3L-8591A-72/B3L-8591A-A0) ...........................................................2

2.

Cable Interface (2CR-8533A-70) ........................................................................4

3.

Wire Harness Set (B3L-F2590-70) .....................................................................6

4.

Wire, Sub-Lead (2KS-82509-70) ........................................................................7

5.

Headlight Harness Set (BX4-F4350-71) ........................................................... 18

6.

Repair set  ........................................................................................................ 19

7.

CCU COMP. (2KS-85800-72) .......................................................................... 21

2-2  Installing Engine Parts ................................................................................26

8.

Maintenance Set (B3L-MAINT-70) ....................................................................26

9.

Spark Plug Set (14B-R465B-70) ...................................................................... 27

10. Sylinder Head Gasket ......................................................................................28
11. Piston Set (2CR-116A0-71) ...............................................................................29
12. Connecting Rod Set (2CR-1165B-70) ...............................................................29
13. Crankshaft (B3L-11400-70) ...............................................................................29
14. High-lift Camshafts for SBK ............................................................................. 31
15. Cam Sprocket for SBK (B3L-12176-70) ............................................................ 31
16. Cam Sprocket ASSY. for SST(B3L-12177-70) ...................................................34
17. Valve Spring Set (2CR-A2110-72) .................................................................... 37
18. Air Funnel Set (B3L-1440B-80) ........................................................................38
19. AIS-plug Set (2CR-A4890-70) ..........................................................................40
20. Clutch Spring Spacer(B3L-16332-70) ............................................................... 41
21. Cluch boss set (B3L-16370-70) ........................................................................ 42
22. Transmission Gear ...........................................................................................43
23. Mission Maintenance Set (2CR-A7000-70) ......................................................46
24. Drive Sprockets ................................................................................................49
25. Sprocket Nut Set (2CR-A7463-70) ...................................................................50
26. Strainer Cover Set (2CR-13400-71) .................................................................. 51
27. Strainer Cover Set (B3L-13400-70) ..................................................................56

2-3  Installing Chassis Parts ..............................................................................62

28. Spring Rear Shock ...........................................................................................62
29. Spring Front Fork .............................................................................................63
30. Seat Cushion (13S-24713-70) ...........................................................................65
31. Front Spare Wheel ASS’Y (2CR-25100-70) .....................................................66
32. Rear Spare Wheel ASS’Y (B3L-25300-70) ......................................................67
33. Rear Sprocket ..................................................................................................68
34. Front Caliper Piston set (B3L-25809-70) ..........................................................68
35. Tube Guide (B3L-26243-70) .............................................................................69

3  Tightening Torque List .............................................................................. 70

Tightening the Cylinder Head ...................................................................................83
Installing the Crankcase ...........................................................................................84
Procedure to tighten the aluminum bolts ..................................................................85
When replacing aluminum bolts with iron bolts.........................................................86
Procedure to install the engine ................................................................................. 87
Procedure to install the pivot shaft peripheral parts .................................................88

4  Headlight Cord Wiring Diagram ............................................................... 89
5  YZF-R1 Wiring Diagram ............................................................................ 90

CONTENTS

Summary of Contents for YZF-R1 2022

Page 1: ......

Page 2: ...ly requested not to use them on public roads are subject to change without notice for improvement Parts List Symbols The star mark means that the part is included in the kit set and is a genuine Yamaha part Therefore you can easily purchase the part at any Yamaha part dealer when necessary The circle mark means that although the part is included in the kit set it can also be purchased individually...

Page 3: ... 40 20 Clutch Spring Spacer B3L 16332 70 41 21 Cluch boss set B3L 16370 70 42 22 Transmission Gear 43 23 Mission Maintenance Set 2CR A7000 70 46 24 Drive Sprockets 49 25 Sprocket Nut Set 2CR A7463 70 50 26 Strainer Cover Set 2CR 13400 71 51 27 Strainer Cover Set B3L 13400 70 56 2 3 Installing Chassis Parts 62 28 Spring Rear Shock 62 29 Spring Front Fork 63 30 Seat Cushion 13S 24713 70 65 31 Front ...

Page 4: ...13 0 13 0 Valve timing event angle INT 105 108 106 108 EXT 109 110 109 110 Clearance between valve and piston minimum INT 0 95 mm 0 95mm EXT 1 90 mm 1 95mm Valve tappet clearance INT 0 09 0 17 mm 0 09 0 17 mm 0 09 0 17 mm EXT 0 18 0 23 mm 0 18 0 23 mm 0 18 0 23 mm Squish recommended value INT 0 65 0 75 mm 0 65 0 75 mm 0 65 0 75 mm EXT 0 95 1 05 mm 0 95 1 05 mm 0 95 1 05 mm Recommended value when i...

Page 5: ...manual in the CD ROM that comes with the set Web https www akrapovic com en intro returnUrl 2F 1 ECU Set B3L 8591A 72 B3L 8591A A0 No PART No PART NAME Q TY REMARKS 1 B3L 8591A A0 ECU SET for SST 1 2 B3L 2818Y 73 CD 1 YMS SOFT MANUAL ECU of this set The base data for SST is for standard engine Both for SBK and SST the mode can be switched between Sprint and EWC by inserting and removing the 2 pole...

Page 6: ...12170 70 B3L 12180 70 B3L 12176 70 Use with original valve springs of YZF R1 BX4 12113 00 BX4 12114 00 BX4 12123 00 BX4 12124 00 B3L 1440B 70 B3L 8591A 71 B3L F2590 70 R1 B3L 83500 00 R1M B4S 83500 00 2020 2021 2022 for SST Use with original cam shaft of YZF R1 B3L 12170 00 Use with original cam shaft of YZF R1 B3L 12180 00 Use with original cam sprocket of YZF R1 Use with original valve springs o...

Page 7: ...ed with a self diagnostic function in order to ensure that the fuel injection system is operating normally If this function detects a malfunction in the system it immediately operates the engine under substitute characteristics and illuminates the engine trouble warning light to alert the rider that a malfunction has occurred in the system Once a malfunction has been detected a fault code is store...

Page 8: ...r A Circuit High Bank 1 or Single Sensor P0351 Ignition Coil A Primary Control Circuit Open P0352 Ignition Coil B Primary Control Circuit Open P0353 Ignition Coil C Primary Control Circuit Open P0354 Ignition Coil D Primary Control Circuit Open DTC CODE P0475 Exhaust Pressure Control Valve A P0476 Exhaust Pressure Control Valve A Range Performance P0480 Fan 1 Control Circuit P048B Exhaust Pressure...

Page 9: ...LEAD for FUEL PUMP 1 6 B3L 83553 70 WIRE LEAD for METER 1 7 B3L 2128A 70 BRKT REGULATOR 1 1 For REC REG 8 92017 06020 BOLT BUTTON HEAD 2 9 90201 07081 WASHER PLAIN 2 10 95607 06200 NUT U FLANGE 2 11 B3L 2331W 70 BRKT UPPER 1 For ECU 12 B3L 2331X 70 BRKT UNDER 1 For ECU 13 90338 06018 PLUG 4 14 90111 06116 BOLT HEX SOCKET BUTTON 1 M6 16mm 15 90111 06140 BOLT HEX SOCKET BUTTON 1 M6 20mm 16 95817 060...

Page 10: ...not work without the connection Do not disassemble the Hydraulic unit assy TIP used removing its coupler will pose no problem No PART No PART NAME Q TY REMARKS 21 2KS 82509 70 WIRE SUB LEAD 1 SCU 4 WIRE SUB LEAD 2KS 82509 70 Parts List This wire harness is for mounting the KIT harness to a vehicle with the Electric racing suspension ERS function NOTICE time use YMS to perform writing of the base m...

Page 11: ...s 2 Remove the side cover bracket left from the vehicle 3 Install the PLUG13 to the BRKT UNDER12 4 Install the BRKT UNDER12 using the BOLT HEX SOCKER BUTTON 14 and15 to the frame 5 Install the ECU and BRKT UPPER 11 using theBOLT FLG 16 to the BRKT UNDER12 R1 EN2911 2019Rev ...

Page 12: ...rvo motor from the vehicle Install the Hydraulic unit using the B O LT B U T T O N H E A D 19 t o t h e BRKT CONTROL UNIT17 7 Install the BRKT CONTROL UNIT 17 using the STD Bolt and collar BOLT HEX SOCKET HEAD18 to the vehicle R1 EN2911 2019Rev ...

Page 13: ...ULATOR 1 7 using the NUT U FLANGE 10 8 Remove from the chassis the STD rectifier regulator that is installed on the right side of the radiator 9 Install the BRKT REGULATOR 1 7 using the BOLT BUTTON HEAD 8 and WASHER PLAIN 9 to the vehicle R1 EN2911 2019Rev ...

Page 14: ...H INJECTOR REC REGU FUEL PUMP PC I F SELECT SW LIGHT SW NEUTRAL SW ABS ECU OBD CCU IMU FUSE BOX RR WHEEL SENSOR BTRY MINUS TAIL LIGHT POWER SUPPLY RELAY ASSY STARTER RELAY MAIN FUSE BTRY PLUS EG EARTH GP SENSOR OIL SW SHIFT SENSOR TPS ACM CRANK SHAFT SENSOR ECU POWER SUPPLY SCU 11 Install the wire harness of the kit as the diagram indicate the names of parts to be connected R1 EN2911 2019Rev ...

Page 15: ... 12 METER MAIN SW AC INJECTOR 2 AC INJECTOR 1 AC INJECTOR 3 AC INJECTOR 4 indicate the names of parts to be connected R1 EN2911 2019Rev ...

Page 16: ...R 1 PRESSUER SENSOR Pb THROTTLE MOTOR WATER TEMP SENSOR STD SUB LEAD for WATER TEMP SENSOR SELECT SW AC INJECTOR B3L 82309 70 PC I F FUEL PUMP 2CR 8231Y 70 NEUTRAL SW LIGHT SW REC REGU VI MOTOR AIR TEMP SENSOR IG COIL 3 IG COIL 1 IG COIL 2 B3L 82386 70 indicate the names of parts to be connected R1 EN2911 2019Rev ...

Page 17: ... 14 The name and function of each switch Left Right R1 EN0102 2022Rev ...

Page 18: ...ensors that measure a machine pitch b roll and c yaw and three G sensors accelerometer that measure acceleration in the forward backward up down and right left directions YRC controls the engine output based on data received from those sensors PWR Power Delivery Mode The power mode selection system consists of valve opening depending on the degree of throttle opening thus providing the rider with ...

Page 19: ...ly assisted shifting When the sensor on the shift rod detects the appropriate motion in the shift pedal engine power output is momentarily adjusted to allow for the gear change to occur LIF Lift control system The lift control system reducing wheel lift rate during extreme acceleration such as during starts or out of corner acceleration When front wheel lift is detected by the IMU engine output is...

Page 20: ...tandard part too create a mount for the sensor assembly and attach the front and rear wheel sensors referring to the diagram below 1 When manufacturing a rotor and sensor use a steel type material with magnetic properties 2 Make the angle of attachment in the rotation direction of the rotor of the sensor assembly the same as the angle indicated in the diagram below 3 If you change the rotor sensor...

Page 21: ...urning on the STD headlights and taillights It assumes that the standard headlights and taillights are used There are three light switches SW 1 Turns on the headlight high beam and taillight 1 SW 2 Turns on the headlight low beam and taillight 2 EMERGENCY SW Turns on the emergency light Use the appropriate light according to the racing rules of the endurance race Diagram at the tip of the tube Par...

Page 22: ...85970 00 FR WHEEL SENSOR 1 5 2CR 85980 00 RR WHEEL SENSOR 1 Parts List No PART No PART NAME Q TY REMARKS 1 2CR 83500 00 METER ASSY 1 2 2CR 83963 00 SWITCH HANDLE 3 1 3 2CR 83969 00 SWITCH HANDLE 5 1 4 2CR 85970 00 FR WHEEL SENSOR 1 5 2CR 85980 00 RR WHEEL SENSOR 1 Parts List No PART No PART NAME Q TY REMARKS 1 1 2 1 3 1 4 1 5 1 Parts List R1J20191108Rev R1J20191108Rev R1 EN0102 2022Rev ...

Page 23: ...t 2KS 28130 70 No PART No PART NAME Q TY REMARKS 1 2KS 83500 60 METER ASSY 1 2 2CR 83963 00 SWITCH HANDLE 3 1 3 2CR 83969 00 SWITCH HANDLE 5 1 4 2CR 85970 00 FR WHEEL SENSOR 1 5 2CR 85980 00 RR WHEEL SENSOR 1 Parts List No PART No PART NAME Q TY REMARKS 1 METER ASSY 1 2 SWITCH HANDLE 3 1 3 SWITCH HANDLE 5 1 4 FR WHEEL SENSOR 1 5 RR WHEEL SENSOR 1 Parts List R1J20191108Rev R1YEC20191005Rev R1 EN010...

Page 24: ... the explanation of the store application in addition to this manual R1 EN2911 2019Rev Parts List No PART No PART NAME Q TY REMARKS 1 2KS 85810 72 CCU ASSY 1 dedicated software embedded 2 2KS 88107 00 GPS unit 1 3 2KS 85721 71 Sub harness 1 Application Download from App Store Google Play Store Components CCU ASSY dedicated software embedded GPS unit Sub harness Application Download from App Store ...

Page 25: ...up on the meter before riding It may take about 10 minutes for GPS Since the GPS and oil pressure warning icons are at the same location the GPS icon does not light up when the the oil pressure warning icon lights up such as NOTICE If GPS positioning is not available it will Download the application onto the tablet TIP For Android visit Google Play Store and For iOS visit App Store and download Y ...

Page 26: ...the logging mode of the CCU to Track See Fig 2 Y TRAC for iOS version CCU While riding After riding Download the logging data from the CCU Y TRAC CCU Display the logging data with map Y TRAC Internet Usage Fig 1 Fig 2 TIP When connecting the tablet to the network select CCU when communicating with Connecting to the CCU Label on the CCU See Fig 3 Network name SSID YAMAHA MOTOR CCU MAC aa bb cc dd e...

Page 27: ...nged according to the specification of the installed sensor To change the display value tap AIN Setting Example 1 When the following is stated in the sensor s manual AF value voltage x 1 6 10 Factor 1 6000 10 0000 Min Y axis 10 00 Max Y axis 20 00 Min Y axis and Max Y axis can be any Example 2 When the following is stated in the sensor s homepage AF value output voltage x 14 7 3 Factor 4 9000 0 00...

Page 28: ...heel switch operation procedure Press the wheel switch to blink area 1 Rotate the wheel switch to blink area 2 Press and hold the wheel switch to blink only column and period in area 2 This operation is required each time after the main switch is set to ON TIP Regardless of the meter setting lap data will be recorded in the logging data when line passing is detected ...

Page 29: ...onnecting rod bolts should be used in their original condition Do not apply any oil or degrease Be careful not to get engine oil or grease on the bolt seat surface or threads If oil is applied or degrease replace the bolts with new ones Use only new bolts for assembly and do not reuse them Angle tightening method 1 Degrease the bolt seat surface and female thread on the connecting rod side and all...

Page 30: ... semi surface discharge type of shape TIP Since these spark plugs have a copper gasket caution is needed during installation on the following points 1 The tightening torque is 12 15 N m 2 When not checking the torque tighten by rotating through 30 after manual tightening in the case of new plugs When reusing plugs tighten by rotating through 15 ...

Page 31: ...g equipment 1 Burette 2 Clear plastic plate 3 Oil 3 1 mixture of torque converter oil and white gasoline 4 Vaseline to seal the valve and the plastic plate Measurement method 1 Tighten a regulation spark plug to the regulation torque in the cylinder head to be measured 2 Set so that the alignment surface of the combustion chamber is level 3 Apply a thin coat of Vaseline to the valve face and set t...

Page 32: ...g Rod Set 2CR 1165B 70 Parts List No PART No PART NAME Q TY REMARKS 1 2CR 11650 00 CONN ROD ASSY 1 4 This set consists of four genuine connecting rod assemblies and the weight difference of each item does not exceed 2 g and combine them so that the small end weights are uniform by Yamaha s measuring method Parts List No PART No PART NAME Q TY REMARKS 1 B3L 11400 70 CRANK ASSY 1 This item is a genu...

Page 33: ...set enables installing those items on any model year engine at once Connecting rod No change Crankshaft As a thrust bearing is added to the 4 cylinder for the 2016 to 2022 model engine the 2015 model and 2016 to 2022 models are not compatible each other The 2015 model crankshaft is currently not available in the kit Please purchase a Yamaha genuine part when a 2015 model crankshaft is needed MODEL...

Page 34: ...g the long holes on the cam sprocket No PART No PART NAME Q TY REMARKS 1 B3L 12170 80 SHAFT CAM 1 1 INT 2 B3L 12180 80 SHAFT CAM 2 1 EXT No PART No PART NAME Q TY REMARKS 3 B3L 0012176 70 SPROCKET CAM 1 INT EXT shared use Tightening torque R1 EN0102 2022Rev ...

Page 35: ...ce the outside of the engine Installation 1 Fit the scratch line on the camshaft to the compression top dead point 105 degree K mark position to combine the camshaft and cylinder head surface 2 Adjust the valve timing to the value stated on the normal specifications using the long holes How to position at 1 cylinder s compression top dead point 105 Position to install the cam sprocket at 1 cylinde...

Page 36: ...12170 70 B3L 12180 70 B3L 12176 70 Use with original valve springs of YZF R1 BX4 12113 00 BX4 12114 00 BX4 12123 00 BX4 12124 00 B3L 1440B 70 B3L 8591A 71 B3L F2590 70 R1 B3L 83500 00 R1M B4S 83500 00 2020 2021 2022 for SST Use with original cam shaft of YZF R1 B3L 12170 00 Use with original cam shaft of YZF R1 B3L 12180 00 Use with original cam sprocket of YZF R1 Use with original valve springs o...

Page 37: ...anges the valve timing to improve the output 2 Remove the STD cam sprocket from the camshaft using a press machine 3 Align the center of the screw hole of the cam sprocket holder with the phase of the mark until the end face of the cam sprocket holder meets the end face of the camshaft Installation 1 Mark the camshaft end face on the sprocket mountain centerline at the I mark on the INT EXT cam sp...

Page 38: ...d the B3L mark are diagonal 5 When assembling to the cylinder head align the center of the two exhaust marks on the kit cam sprocket with the top surface of the exhaust side cylinder head 12 2N m 12 2N m B3L mark 2 punches EXT alignment mark A punch INT alignment mark R1 EN0102 2022Rev ...

Page 39: ...12170 70 B3L 12180 70 B3L 12176 70 Use with original valve springs of YZF R1 BX4 12113 00 BX4 12114 00 BX4 12123 00 BX4 12124 00 B3L 1440B 70 B3L 8591A 71 B3L F2590 70 R1 B3L 83500 00 R1M B4S 83500 00 2020 2021 2022 for SST Use with original cam shaft of YZF R1 B3L 12170 00 Use with original cam shaft of YZF R1 B3L 12180 00 Use with original cam sprocket of YZF R1 Use with original valve springs o...

Page 40: ...A 71 2CR 8591A 72 2017 2018 2019 2CR 12170 70 2CR 12180 70 B3L 12176 70 2CR A2110 71 2CR A2110 72 2CR 1440B 70 BX4 8591A 70 BX4 8591A 71 BX4 F2590 70 R1 BX4 83500 30 R1M 2KS 83500 60 2020 2021 2022 B3L 12170 70 B3L 12180 70 B3L 12176 70 Use with original valve springs of YZF R1 BX4 12113 00 BX4 12114 00 BX4 12123 00 BX4 12124 00 B3L 1440B 70 B3L 8591A 71 B3L F2590 70 R1 B3L 83500 00 R1M B4S 83500 ...

Page 41: ...ol You can use the Ycci system as the kit funnel You can control the operation timing by using the YMS software packed together with the kit ECU You can also control the STD funnel by using the YMS software No PART No PART NAME Q TY REMARKS 1 B3L 14479 80 SECONDARY FUNNEL 1 2 B3L 14469 80 PRIMARY FUNNEL 1 1 3 92014 06025 BUTTON HEAD BOLT 3 4 B3L 1446C 80 PRIMARY FUNNEL 2 1 5 92014 06025 BUTTON HEA...

Page 42: ...12170 70 B3L 12180 70 B3L 12176 70 Use with original valve springs of YZF R1 BX4 12113 00 BX4 12114 00 BX4 12123 00 BX4 12124 00 B3L 1440B 70 B3L 8591A 71 B3L F2590 70 R1 B3L 83500 00 R1M B4S 83500 00 2020 2021 2022 for SST Use with original cam shaft of YZF R1 B3L 12170 00 Use with original cam shaft of YZF R1 B3L 12180 00 Use with original cam sprocket of YZF R1 Use with original valve springs o...

Page 43: ...e hose attached to the cylinder head cover and the air cut off valve accompanying the hose 2 the reed valve and plate from inside 3 Install the 1 PLATE 2 5SL 1482L 70 in replacement of the cap Be sure to apply liquid gasket 4 Remove the cylinder head cover and the four collars fitted to the head cover and install the 2 PLUG BLIND 2CR A4890 70 5 After removing the hose connected to assembly insert ...

Page 44: ...AR 3 This spacer is intended to reduce rear tire hopping during deceleration Installation 1 Install between the pressure plate 1 and the pressure plate 2 2 Remove the clutch cover damper plate and clutch cover damper from the clutch cover then install the clutch cover ...

Page 45: ...REMARKS 1 B3L 16371 70 BOSS CLUTCH 1 2 B3L 16350 70 PRESSURE PLATE ASSY 1 1 By using this part together with Clutch Spring Spacer B3L 16332 70 the hopping of the rear tire during deceleration can be further reduced R1 EN0102 2022Rev ...

Page 46: ...TH PINION B 1 6 2CR 17161 70 GEAR 6TH PINION A 1 7 2CR 17161 80 GEAR 6TH PINION B 1 8 2CR 17402 00 DRIVE AXLE ASSY 1 9 2CR 17211 70 GEAR 1ST WHEEL 1 10 2CR 17221 70 GEAR 2ND WHEEL 1 11 2CR 17231 70 GEAR 3RD WHEEL 1 12 2CR 17241 70 GEAR 4TH WHEEL 1 13 2CR 17251 70 GEAR 5TH WHEEL A 1 14 2CR 17251 80 GEAR 5TH WHEEL B 1 15 2CR 17261 70 GEAR 6TH WHEEL A 1 16 2CR 17261 80 GEAR 6TH WHEEL B 1 R1 EN2911 20...

Page 47: ...e combine standard gear Gear ratio STD KIT 1st 39 15 2 600 39 16 2 438 2nd 37 17 2 176 35 17 2 059 3rd 35 19 1 842 34 19 1 789 4th 30 19 1 579 33 21 1 571 5th A 29 21 1 381 32 22 1 455 5th B 31 22 1 409 6th A 30 24 1 250 30 22 1 364 6th B 33 25 1 320 R1 EN2911 2019Rev ...

Page 48: ...268 3 264 1 263 2 262 4 KIT B 25 33 1 32 328 2 319 8 311 8 307 7 304 2 299 8 296 9 292 3 290 0 287 2 285 1 283 4 279 8 278 4 277 1 272 8 271 9 271 1 GEAR PLAN Ratio 14 15 16 16 15 14 16 15 14 15 14 15 14 15 14 14 14 14 P W 41 44 47 48 45 42 49 46 43 47 44 48 45 49 46 47 48 49 1st STD 15 39 2 60 135 1 134 9 134 7 131 9 131 9 131 9 129 2 129 0 128 8 126 3 125 9 123 7 123 1 121 1 120 4 117 9 115 4 11...

Page 49: ... 3 27 90387 31003 COLLAR 3 28 90209 28008 WASHER 9 29 93440 31187 CIRCLIP 9 30 90387 28004 COLLAR 6 31 90214 29002 WASHER CLAW 3 32 90214 28002 WASHER CLAW 3 33 90387 25008 COLLAR 3 34 93102 40330 SEAL OIL 3 35 93440 62032 CIRCLIP 3 36 90201 257H0 WASHER PLAIN 3 37 93306 27214 BRG 3 38 5VY 17166 00 BRG 2 3 This kit contains three 3 sets of parts necessary for transmission disassembly and maintenan...

Page 50: ... 47 ...

Page 51: ... 48 Transmission Assembly ...

Page 52: ... Q TY REMARKS 1 2CR 17460 74 SPROCKET DRIVE 1 14T 520SIZE 2 2CR 17460 75 SPROCKET DRIVE 1 15T 520SIZE 3 2CR 17460 76 SPROCKET DRIVE 1 16T 520SIZE This sprocket is weight saved by changing the chain size to 520 in relation to the STD one ...

Page 53: ... 50 Parts List No PART No PART NAME Q TY REMARKS 1 90179 22018 NUT 3 2 90208 22002 WASHER CONICAL SPRG 3 ...

Page 54: ...R 13416 71 PIPE OIL 1 1 8 93210 14003 O RING 3 6 7 attachment Grease outer surface 9 90110 06393 BOLT HEX SOCKET 1 6 attachment 10 90110 06182 BOLT HEX SOCKET 1 7 23 attachment 11 2CR 13161 70 PIPE DELIVERY 1 1 12 90480 13010 GROMMET 1 1 11 23 attachment 13 5VY 13117 10 COLLAR DISTANCE 1 1 11 23 attachment 14 90109 06015 BOLT 1 1 11 23 attachment 15 2CR 1310A 70 PAN OIL 1 The number of the oil win...

Page 55: ...T HEX SOCKET 3 Attach PIPE OIL 1 and BRKT STRAINER 1 to the engine by using 8 O RING and 10 BOLT HEX SOCKET tighten PIPE OIL 1 together with BRKT STRAINER 1 3 4 2 6 23 7 TIP and 7 PIPE OIL 1 periodically 4 Attach 11 PIPE DELIVERY 1 to the engine 5 Fix 1 STRAINER HSG ASSY to the engine by using 5 BOLT HEX SOCKET and 19 GASKET STRAINER 1 11 5 19 ...

Page 56: ...Attach 20 BAFFLE PLATE to PAN OIL by using 21 BOLT 6 Fix STRAINER HSG ASSY 11 PIPE DELIVERY 1 and 23 BRKT STRAINER 1 by u si n g G RO M M E T COLLAR DISTANCE BOLT and WASHER PLAIN 1 11 23 1 11 13 12 14 22 23 ...

Page 57: ... 54 8 Attach 15 PAN OIL to the engine by using 16 BOLT BUTTON HEAD 9 Attach 17 PLUG STRAIGHT SCREW and 18 GASKET to 15 PAN OIL TIP Be sure to check the torque when installing ...

Page 58: ... and check that the oil level is within a range of the upper limit of the oil pan window right side of the vehicle to the lower limit of the engine crank case oil window left side of vehicle If it is out of range adjust the oil level Oil pan window right side of vehicle Engine crank case oil window left side of vehicle ...

Page 59: ...83 00 PLUNGER 1 15 0WS4 90433 00 SPRG 1 16 0WT3 13486 00 RET RELIEF VALVE 1 17 93210 15566 O RING 1 13 attachment 18 91312 06016 BOLT HEX SOCKETHEAD 2 13 attachment 19 0WX2 90012 00 HOSE OIL 1 10 13 attachment 20 2CR 13418 70 PIPE OIL 2 1 21 2CR 13416 71 PIPE OIL 1 1 22 93210 14003 O RING 3 20 21 attachment 23 90110 06393 BOLT HEX SOCKET 1 20 attachment 24 90110 06182 BOLT HEX SOCKET 1 21 34 attac...

Page 60: ... valve passage Installation 1 Assemble 14 15 16 and 17 to 13 2 Secure 13 to the engine with 18 The tightening torque of this set is same as that of STD Use the screw locking solvent and grease same as STD For details refer to the STD service manual published by Yamaha Motor Co Ltd For details on installation of this set see the next page R1 EN0102 2022Rev ...

Page 61: ... with 12 7 Assemble 2 to 1 and fix 2 with 5 and 6 8 Attach 1 and 3 to 10 with 4 3 Pass 22 through 21 and assemble to 20 4 Pass 22 through 20 and secure it to the engine with 23 5 Fasten 21 and 34 to the engine with 24 R1 EN0102 2022Rev ...

Page 62: ... 59 9 Assemble 1 25 and 34 using 7 8 9 and 33 10 Assemble the 19 to the 10 and 13 19 13 10 R1 EN0102 2022Rev ...

Page 63: ... 31 BAFFLE PLATE to 26 PAN OIL by using 32 BOLT 8 Put 30 between 26 and the engine and assemble 26 to the engine with 27 9 Assemble 28 and 29 to 26 TIP Be sure to check the torque when installing R1 EN0102 2022Rev ...

Page 64: ...perature 75 80 C stop the engine and limit of the oil pan window on the right side of the vehicle with the racing rear stand in place Add another 200cc from there Oil pan window right side of vehicle Engine crank case oil window left side of vehicle R1 EN0102 2022Rev ...

Page 65: ... N mm Identifying stamp 159 5 56 98 4 2CR 22222 80 SPRG REAR SHOCK 1 103 N mm Identifying stamp 159 5 56 103 5 2CR 22222 85 SPRG REAR SHOCK 1 108 N mm Identifying stamp 159 5 56 108 There is a stamp on the side of the springs Free length is 159 5 mm for the both STD spring and KIT spring For spring replacement see the 2CR STD Service Manual The spring rate of the standard rear suspension is 88 N m...

Page 66: ...ree lengths are STD spring andKIT spring 219 5mm The spring rate of the STD is 9 0 N mm For information about spring replacement see STD Service Manual R1 EN2911 2019Rev No PART No PART NAME Q TY REMARKS 1 BN6 2314 75 SPRG FRONT FORK 1 9 5 N mm Identifying slits 1 2 BN6 23141 80 SPRG FRONT FORK 1 10 0 N mm Identifying slits 2 ...

Page 67: ... 64 References ...

Page 68: ... 65 Parts List No PART No PART NAME Q TY REMARKS 1 13S 24713 70 CUSHION SEAT 1 Anti slip seat Cut to any size for use ...

Page 69: ...00 CAST WHEEL ASSY 1 2 93900 00030 VALVE RIM 1 3 1SD 2517G 00 ROTOR SENSOR 1 4 2CR 2514A 00 RING WHEEL 1 1 5 90149 05037 SCREW 5 6 93210 47440 O RING 1 This kit does not include a tire This part is the STD wheel bearing spacer air valve and center rotor combined ...

Page 70: ...00 CAST WHEEL ASSY 1 2 B3L 25840 00 DISK BRAKE ASSY 1 3 90111 08085 BOLT HEX SOCKET BUTTON 5 4 93900 00030 VALVE RIM 1 This kit does not include a tire This part is the STD wheel bearing spacer air valve rear disk brake and center rotor combined R1 EN2911 2019Rev ...

Page 71: ... 79 Rr SPROCKET 48T 1 12 B3L 12180 80 Rr SPROCKET 49T 1 This sprocket changes the chain size to 520 for the STD and is lighter weight than tha STD It is used for the STD wheel R1 EN2911 2019Rev No PART No PART NAME Q TY REMARKS 1 4SV 25814 00 FR CALIPER PISTON 30mm 4 2 4SV 25814 10 FR CALIPER PISTON 27mm 4 3 5PW 25815 00 FR CALIPER PISTON SEAL 30mm 4 4 3GM 25816 00 FR CALIPER DUST SEAL 30mm 4 5 5P...

Page 72: ...ngle of the throttle grip when the throttle is fully opened is 57 5 as against STD 67 Except this part all other parts should be STD parts Throttle grip operation angle KIT specification Throttle body opening Fully closed Fully opened R1 0928 2020Rev NOTICE When the tube guide is changed use the the STD KIT ...

Page 73: ...85 0 15 2 CAP x HEAD 90105 06027 BOLT FLANGE M6 x 1 0 When using the bolt continuously Apply oil to the bearing surface and thread part of the bolt and tighten with tightening torque 8 0 1 0 N m 0 8 0 1 kgf m When replacing with a new bolt Tighten with tightening torque 10 0 2 0 N m 1 0 0 2 kgf m It is not necessary to apply oil to the bearing surface and thread part of the bolt Use it in the deli...

Page 74: ...ce and thread part of the bolt and the both sides of the washer SPROCKET CRANK 2CR 12157 00 BOLT M12 x 1 25 72 5 7 2 0 5 1 Apply oil to the bearing surface and thread part of the bolt CAM CHAIN TENSIONER 90110 06178 BOLT HEXAGON SOCKET HEAD M6 x 1 0 10 2 1 0 0 2 2 APPLY TO SCREW ROCKING Install PIPE 1 4 Water pump 90110 06246 BOLT HEXAGON SOCKET HEAD M6 x 1 0 10 2 1 0 0 2 1 APPLY TO SCREW ROCKING ...

Page 75: ... BOLT HEXAGON SOCKET HEAD M6 x 1 0 10 2 1 0 0 2 2 APPLY TO SCREW ROCKING Install oil delivery pipe 2 90110 06182 BOLT HEXAGON SOCKET HEAD M6 x 1 0 10 2 1 0 0 2 2 APPLY TO SCREW ROCKING Install oil delivery pipe 5 90149 06158 SCREW M6 x 1 0 10 2 1 0 0 2 1 APPLY TO SCREW ROCKING Tighten CLEANING BOLT UNION 90401 20008 BOLT UNION M20 x 1 5 70 10 7 0 1 0 1 Apply oil when tightening the case Install OI...

Page 76: ...OOLER 90110 06346 BOLT HEXAGON SOCKET HEAD M6 x 1 0 10 2 1 0 0 2 2 Install the lower of the OIL COOLER 95827 06030 BOLT FLANGE M6 x 1 0 10 2 1 0 0 2 1 Install THROTTLE WIRE 2CR 26302 00 BOLT ADJUSTING M6 3 5 5 5 0 35 0 55 2 JOINT ASSY x THROTTLE BODY 90450 60004 HOSE CLAMP M5 x 0 8 3 0 5 0 3 0 05 4 Collar striking or torque manage ment THROTTLE x FUNNEL 90110 06163 BOLT M6 x 1 0 8 2 0 8 0 2 6 UPPE...

Page 77: ...thod CRANKCASE 1 x CRANKCASE 2 90119 09010 BOLT HEXAGON WITH WASHER M9 x 1 25 FOR DETAILS SEE page 72 Installing the Crank case 10 Apply oil to the thread part and bearing surface Do not reuse a mended part CRANKCASE 1 x CRANKCASE 2 14B 15156 00 BOLT CRANK CASE JOURNAL M8 x 1 25 24 2 2 4 0 2 8 Apply oil to the thread part bear ing surface and O RING part Do not reuse a mended O RING CRANKCASE 1 x ...

Page 78: ... AL bolts 8 ACM COVER Install COVER CHAIN CASE 15418 90110 06387 BOLT HEXAGON SOCKET HEAD M6 x 1 0 10 2 1 0 0 2 3 DRIVE SPROCKET COVER Install COVER CRANK CASE 2 15421 90109 06301 BOLT M6 x 1 0 FOR DETAILS SEE page 73 List of tightening AL bolts 10 CLUTCH COVER Install COVER 1 15416 90109 06299 BOLT M6 x 1 0 FOR DETAILS SEE page 73 List of tightening AL bolts 5 CAM CHAIN COVER Install COVER 15413 ...

Page 79: ...stall PLUG 2CR 15189 00 1 90110 06396 BOLT HEXAGON SOCKET M6 x 1 0 10 2 1 0 0 2 2 Install JOINT 15319 90149 06068 SCREW M6 x 1 0 10 2 1 0 0 2 1 TAKE CARE NOT TO OVERTIGHTEN FOR HYDRAU LIC SENSOR Install PLATE 15113 90110 06108 BOLT HEXAGON SOCKET M6 x 1 0 12 2 1 2 0 2 4 APPLY TO SCREW ROCKING Install IDLER SHAFT 90110 06401 BOLT HEXAGON SOCKET M6 x 1 0 10 2 1 0 0 2 1 APPLY TO SCREW ROCKING Install...

Page 80: ...5067 BOLT HEXAGON SOCKET M5 x 0 8 3 5 0 3 0 5 2 APPLY TO SCREW ROCKING Install NEUTRAL SWITCH 3GB 82540 01 NEUTRAL SWITCH ASSY M10 x 1 25 17 3 1 7 0 3 1 OVERTIGHTEN ING MAY DAM AGE THE PART Install COVER SERVOMOTOR 97702 50514 SCREW TRUSS HEAD TAP PING M5 1 3 0 1 0 3 2 Install THERMO SENSOR for water temperature 4P9 83591 00 THERMO SENSOR ASSY M10 x 1 25 16 2 1 6 0 2 1 SENSOR CAM POSITION 90110 06...

Page 81: ...read dia x pitch Tightening torque N m kgf m Q ty Remarks Install OIL PRES SURE SWITCH LEAD WIRE WS 82504 00 accessory BOLT M4 x 0 7 1 5 2 0 0 15 0 2 1 Install STARTER MOTOR 91312 06030 BOLT HEXAGON SOCKET HEAD M6 x 1 0 10 2 1 0 0 2 2 Engine ...

Page 82: ...ET M12 x 1 25 50 62 5 0 6 2 1 PROCEDURE TO INSTALL THE ENGINE FOR DETAILS SEE page 87 90179 12004 NUT ADJUST BOLT for E G BRACKET REAR 5YU 21495 00 BOLT ENGINE ADJUSTING M18 x 1 0 7 9 0 7 0 9 2 PROCEDURE TO INSTALL THE ENGINE FOR DETAILS SEE page 87 Apply grease or engine oil 10W 30 or 20W 40 equivalent and tighten it Be sure to tighten at the nut side STAY and FRAME on the front side of the tank ...

Page 83: ...010 BOLT M10 x 1 25 31 49 3 1 4 9 1 92902 12600 WASHER PLAIN 90185 12011 NUT SELF LOCKING REAR CUSHION ARM RELAY 90105 10017 BOLT FLANGE M10 x 1 25 31 49 3 1 4 9 1 95602 10200 NUT U FLANGE REAR CUSHION and FRAME 95602 10200 NUT U FLANGE M10 x 1 25 31 49 3 1 4 9 1 90105 10609 BOLT FLANGE ADJUST NUT for CHAIN PULLER 90101 08013 BOLT HEXAGON M8 x 1 25 12 19 1 2 1 9 2 95302 08600 NUT HEXAGON 90201 080...

Page 84: ...0 5 1 REAR STAY for FUEL TANK REAR FRAME 90111 06071 BOLT HEXAGON SOCKET BUTTON M6 x 1 0 5 8 0 5 0 8 4 REAR STAY for FUEL TANK FUEL TANK 95812 06090 BOLT FLANGE M6 x 1 0 3 5 0 3 0 5 1 95702 06500 NUT FLANGE FRONT WHEEL SHAFT NUT 90179 24004 NUT M24 x 100 130 10 0 13 0 1 REAR WHEEL SHAFT NUT 90185 24007 NUT SELF LOCKING M24 x 1 5 160 220 16 0 22 0 1 FRONT CALIPER FRONT FORK 90105 10397 BOLT FLANGE ...

Page 85: ... 82 For reference Tightening torque N m M5 0 8 4 5 7 0 M6 1 0 7 5 12 M8 1 25 18 28 M10 1 25 37 58 M12 1 25 68 108 M14 1 5 105 167 ...

Page 86: ...f 45 N m 4 5 kgf m bolt Then tighten at 15 N m 1 5 kgf m and tighten at rotating angle of 160 Note Do not loosen all bolts at once Repeat loosening and tightening operation one by one bolt TIP The numbers 1 to 10 show the sequence in which the bolts are tightened Apply engine oil to the bearing surface and thread part of the bolt ...

Page 87: ...ning sequence of 1 to 10 to a turn of nut angle of 75 5 4 Tighten the bolts in the tightening sequence of 11 to 20 to 24 2 N m 2 4 0 2 kgf m 5 Tighten the bolts in the tightening sequence of 21 to 40 to 10 2 N m 1 0 0 2 kgf m TIP The numbers 1 to 40 show the sequence in which the bolts are tightened Apply engine oil to the bolts 1 to 10 21 to 27 and 29 to 39 and the both sides of the washer Apply ...

Page 88: ... m 2 In the following order loosen each bolt tighten at 3 N m 0 3 kgf m and apply snap and angle tightening at rotating angle of 90 Note Do not loosen all bolts at once Repeat loosening and tightening operation one by one bolt TIP The numbers 1 to 12 show the sequence in which the bolts are tightened ...

Page 89: ...LT HEXAGON SOCKET M6 x 1 0 12 2 1 2 0 2 12 APPLY TO SCREW ROCKING STRAINER COVER Install COVER CRANK CASE 1 15411 90110 06387 BOLT HEXAGON SOCKET M6 x 1 0 12 2 1 2 0 2 8 ACM COVER Install COVER CRANK CASE 2 15421 90110 06388 BOLT HEXAGON SOCKET M6 x 1 0 12 2 1 2 0 2 10 CLUTCH COVER Install COVER 1 15416 90110 06396 BOLT HEXAGON SOCKET M6 x 1 0 12 2 1 2 0 2 5 CAM CHAIN COVER Install COVER 15413 901...

Page 90: ...ttach the bolt 4 temporarily 4 Attach the engine mount boss 5 and 6 to the frame COMP temporarily and then attach the bolt 7 temporarily 5 Tighten the two engine adjusting bolts 1 at Check that the bearing surface of the bolts torque Tighten the nut 8 lower side at TIP For information about tightening torque and requirement for lubricant agent see the list of tightening torque ...

Page 91: ... Tighten the pivot shaft 1 at specified torque 3 Tighten the nut 3 self rocking at Be sure to secure the pivot shaft 1 so that it is not co rotated TIP For information about tightening torque and requirement for lubricant agent see the list of tightening torque ...

Page 92: ... 89 4 ...

Page 93: ......

Page 94: ... M A I N _ H A R N E S S CCU1_SUB_LEAD L B L W B W R G M A I N _ H A R N E S S WIRE_SUB_LEAD_11 WT B L G W RELAY_ASSY Br W R W R L L R L W R W BLACK ECU2 R W Y B L L Y L G W W B B G B B Y B B L BLACK ECU1 Gy R Or Gy G Or G Y R B G B R B Or B L B Lg R B Sb W W L Br B Br Y R L B W B W R L Sb Y L L W R G BLACK ECU3 Gy L R L V P P W L B W B W B L Br W B Y L W W L Gy B G G W L W L Y G Y OIL_SW G L BOND...

Page 95: ...Published by YAMAHA MOTOR ENGINEERING co LTD ...

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