Yamaha YZF-R1 Kit Manual Download

Page: 1 / 77

Summary of Contents for YZF-R1

Page 1: ......

Page 2: ...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 pa...

Page 3: ...nel Set 2CR 1440B 70 31 15 AIS plug Set 2CR A4890 70 32 16 Screw cap set 2CR 15171 70 33 17 Transmission Gear 34 18 Mission Maintenance Set 2CR A7000 70 37 19 Drive Sprockets 40 20 Sprocket Nut Set 2C...

Page 4: ...rolled speed 14500 rpm 14500 rpm 14500 rpm Compression ratio recommended value 13 0 13 4 Depending on head surface grinding 13 0 13 0 Valve timing event angle INT 105 108 108 EXT 108 110 110 Clearance...

Page 5: ...set There are two types of basic control data for the ECU included in this set SB Super Bike and ST Stock Sports They can be switched over and vice versa To make it in the ST specification just remov...

Page 6: ...ombination NOTICE Using in other combinations may possibly damage the engine Be sure to use in the combination as stated above MODEL CAMSHAFT IN CAMSHAFT EX VALVE SPRING ECU AIR FUNNEL SET 2015 2CR 12...

Page 7: ...rottle position sensor signal 1 02 Atmospheric pressure 03 Intake air pressure 05 Air temperature 06 Coolant temperature 07 Rear vehicle speed pulse 09 Fuel system voltage battery voltage 13 Throttle...

Page 8: ...n the kit provide the functions for the following codes of standard self diagnosis ODO 0 km FUEL CON L 1 N 2 km h 1000 r min MODE A PWR 4 TCS 2 SCS 2 90 17 12 00 2 1 CODE Description 14 Intake pressur...

Page 9: ...es for lights NOTICE Do not remove the AC generator but leave it to function Use on the battery alone will make the machine unable to run in a short time This wire harness only works when used in comb...

Page 10: ...installation area for fixing for BRKT 4 12 seat 13 14 11 7 3 20 R6 3 Install PLUG 13 to BRKT 4 12 By using the STD battery box installation bolt and bolt 15 install BRKT 4 12 to the shaped battery bo...

Page 11: ...sis the STD rectifier regulator that is installed on the right side of the radiator Install the rectifier regulator using the bracket regulator 7 grommets 8 spacers 9 bolts 10 and nuts 11 Face the bra...

Page 12: ...SELECT SW CRANK SHAFT SENSOR VI MOTOR HANDLE SW LH RH E SD SOLENOID METER SUB LEAD FR WHEEL SENSOR APS THROTTLE MOTOR PRESSURE SENSOR Pa PRESSURE SENSOR Pb 2KS STD SUB LEAD MAIN SW METER AIR TEMP SENS...

Page 13: ...MAIN SW E SD SOLENOID ACM FUSE BOX1 RR WHEEL SENSOR ABS ECU IMU ECU1 2 ST RELAY1 RELAY ASSY POWER SUPPLY INJECTOR 12 22 32 42 WATER TEMP SENSOR FUEL PUMP NEUTRAL SW EG EARTH PC I F INJECTOR 11 21 31...

Page 14: ...11 PRESSURE SENSOR Pa PRESSURE SENSOR Pb VI MOTOR FR WHEEL SENSOR THROTTLE MOTOR APS indicate the names of parts to be connected...

Page 15: ...12 ECU2 2KS 2161E 70 BRKT 4 12 MAIN FUSE ECU1 POWER SUPPLY ST RELAY RELAY ASSY ABS ECU FUSE BOX1 IMU RR WHEEL SENSOR indicate the names of parts to be connected...

Page 16: ...LAP switch Keep the switch at low position Hi position the LAP switch becomes non functional Pit road limiter ON ON PUSH OFF Not used Mode switch Up button Center button Down button MAP SELECT MAP 1 M...

Page 17: ...ckward 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 four different con...

Page 18: ...nt and vehicle control to reduce stress during starts LCS works in conjunction with TCS and LIF systems If TCS is set to OFF LIF is also set to OFF automatically QSS Quick shift system The quick shift...

Page 19: ...netic 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 or s...

Page 20: ...t assumes that the standard headlights and taillights are used When using STD headlights you can use the coupler of either HEAD LIGHT 1 or HEAD LIGHT 2 Diagram 1 The headlight lights up on both the Hi...

Page 21: ...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 2KS 28130 70 No PART No PART NAME Q TY REMA...

Page 22: ...refer to the OWNER S MANUAL for the vehicle or the explanation of the store application in addition to this manual Parts List No PART No PART NAME Q TY REMARKS 1 2KS 85810 70 CCU ASSY 1 dedicated sof...

Page 23: ...TRIP 2 1234 5 km 1 N 2 km h 1000 r min MODE A PWR 1 TCS 1 SCS 1 A 1 LCS QS LIF GPS 12 00 Since the GPS and oil pressure warning icons are at the same location the GPS icon does not light up when the...

Page 24: ...ack See Fig 2 CCU Config 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...

Page 25: ...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 Offset 10 0000...

Page 26: ...TEST 40 03 06 1000 r min A 2 QS LIF GPS 12 00 ABERAGE 2 1 Wheel switch operation procedure Press the wheel switch to blink area 1 Rotate the wheel switch to blink area 2 Press and hold the wheel switc...

Page 27: ...STEM OIL 2 24 INT 7 4TE 12119 00 SEAL VALVE STEM OIL 24 EXT 8 2CR 13414 70 GASKET STRAINER 3 OIL PAN 9 2CR 15451 70 GSKT CRANKCASE COVER 1 3 CLUTCH 10 2CR 15461 70 GSKT CRANKCASE COVER 2 3 CLUTCH 11...

Page 28: ...is of a 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 1 2 1 5...

Page 29: ...not exceed 0 5 g 10 Connecting 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 w...

Page 30: ...atible each other be sure to use a combination of a piston and a piston ring of same model year Since the piston set of the kit consists of pistons piston rings and piston pins the set enables install...

Page 31: ...List 1 3 2 Tightening torque 24 2Nm Possible to adjust the valve timing using the long holes on the cam sprocket USE THESE OVAL HOLES FOR TIMING ADJUSTMENT The set of the camshaft valve spring ECU and...

Page 32: ...cylinder head surface 2 Adjust the valve timing to the value stated on the normal specifications using the long holes TIP For valve timing adjustment refer to the KIT TOOL MANUAL How to position at 1...

Page 33: ...s of a valve spring and a valve spring seat Do not those parts in other combination The set of the camshaft valve spring ECU and air funnel must be used in the following combination NOTICE Using in ot...

Page 34: ...ntrol the STD funnel by using the YMS software No PART No PART NAME Q TY REMARKS 1 2CR 14479 70 SECONDARY FUNNEL 1 2 2CR 14469 70 PRIMARY FUNNEL 1 1 3 92014 06025 BUTTON HEAD BOLT 3 4 2CR 1446C 70 PRI...

Page 35: ...lve accompanying the hose 2 Remove the cap fitted to the hose remove 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...

Page 36: ...ts List No PART No PART NAME Q TY REMARKS 1 90109 06300 BOLT 8 ACM M6 25 AL 2 90109 06301 BOLT 10 CLUCH M6 30 AL 3 90109 06299 BOLT 5 PICK UP M6 20 AL 4 90109 06300 BOLT 8 BREATHER M6 25 AL 5 90109 06...

Page 37: ...N 1 3 2CR 17131 70 GEAR 3RD PINION 1 4 2CR 17151 70 GEAR 5TH PINION 1 5 2CR 17161 70 GEAR 6TH PINION 1 6 2CR 17402 00 DRIVE AXLE ASSY 1 7 2CR 17211 70 GEAR 1ST WHEEL 1 8 2CR 17221 70 GEAR 2ND WHEEL 1...

Page 38: ...gearbox Kit gears cannot use 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 29 21 1 381 3...

Page 39: ...292 6 288 1 287 1 286 3 KIT 22 30 1 36 317 7 309 5 301 8 297 8 294 4 290 2 287 4 282 9 280 7 278 0 276 0 274 4 270 8 269 5 268 3 264 1 263 2 262 4 GEAR PLAN The number of teeth Ratio 14 15 16 16 15 1...

Page 40: ...4 25003 WASHER CLAW 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...

Page 41: ...38 36 38 33 29 29 34 21 22 22 24 23 23 35 25 26 37 28 30 32 31 30 28 28 29 27...

Page 42: ...pline threads Circlip Shaft Edge PortionR Edge Detail of installation of washer Detail of installation of washer Shaft Washer Washer Matching mark Matching mark Portion R Washer Gear The seal side sho...

Page 43: ...PART NAME 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...

Page 44: ...1 20 Sprocket Nut Set 2CR A7463 70 Parts List No PART No PART NAME Q TY REMARKS 1 90179 22018 NUT 3 2 90208 22002 WASHER CONICAL SPRG 3 The OUT mark must face outward Apply swage after tightening a nu...

Page 45: ...0 13010 GROMMET 1 11 attachment 13 5VY 13117 10 COLLAR DISTANCE 1 11 attachment 14 90110 06172 BOLT HEX SOCKET 1 11 attachment 15 2CR 1310A 70 PAN OIL 1 16 92012 06025 BOLT BUTTON HEAD 12 15 attachmen...

Page 46: ...ngine by using 8 O RING and 9 BOLT HEX SOCKET and attach 7 PIPE OIL 1 to the engine by using 10 BOLT HEX SOCKET Attach 2 SPACER to the engine by using 3 O RING and 4 BOLT BUTTON HEAD 620 LT 620 6 7 2...

Page 47: ...5 BOLT HEX SOCKET and 19 GASKET STRAINER 1 4 Attach 20 BAFFLE PLATE to 15 PAN OIL by using 21 BOLT 21 21 21 620 LT 620 20 15 5 Attach 15 PAN OIL to the engine by using 16 BOLT BUTTON HEAD 15 6 Attach...

Page 48: ...hether the oil level is in the range of the upper limit of the oil pan upper window at the right side of vehicle and the lower limit of the engine crank case oil window at the left side of vehicle If...

Page 49: ...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 for rate i...

Page 50: ...RK 1 10 5 N mm Identifying slits 4 There are slits at the ends of the spring for rate identification A0 8 5 N mm 70 9 0 N mm 75 9 5 N mm 80 10 0 N mm 85 10 5 N mm There are slits at the ends of the sp...

Page 51: ...ke displacement depending on conditions Braking Load change The harder the brake is applied the more the load is concentrated on the front Front fork Displaces until stroke has almost bottomed Rear cu...

Page 52: ...49 24 Seat Cushion 13S 24713 70 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 53: ...EMARKS 1 2CR 25160 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 t...

Page 54: ...E Q TY REMARKS 1 2CR 25370 00 CAST WHEEL ASSY 1 2 2CR 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...

Page 55: ...p when the throttle is fully opened is 57 5 as against STD 64 4 Except this part all other parts such as a throttle wire should be STD parts FWD Installation 1 Replace the STD tube guide with the KIT...

Page 56: ...HEAD M6 1 0 12 2 1 2 0 2 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...

Page 57: ...ck that the final tightening torque is 40 0 to 85 0 N m 4 0 to 8 5 kgf m If not replace the bolt with new one and re tight it again 8 each Do not leave EG oil or grease on the bearing sur face or thre...

Page 58: ...0 2 1 Tighten DRAIN BOLT 90340 14019 PLUG STRAIGHT SCREW M14 x 1 5 23 2 4 3 0 4 1 Install PIPE OIL 1 90110 06182 BOLT HEXAGON SOCKET HEAD M6 x 1 0 10 2 1 0 0 2 2 APPLY TO SCREW ROCKING Install HOUSIN...

Page 59: ...OLT HEXAGON SOCKET HEAD M6 x 1 0 10 2 1 0 0 2 2 APPLY TO SCREW ROCKING Tighten the cover side of OIL PIPE COMP 2 90110 06295 BOLT HEXAGON SOCKET HEAD M6 x 1 0 10 2 1 0 0 2 1 APPLY TO SCREW ROCKING Ins...

Page 60: ...GON SOCKET M8 x 1 25 20 2 2 0 0 2 1 Install WIRE PULLEY DOUBLE NUT 2CR 1133E oo WIRE PULLEY 1 M6 x 1 0 5 7 0 5 0 7 2 2CR 1133F oo WIRE PULLEY 2 Install SERVOMOTOR 90110 06106 BOLT HEXAGON SOCKET M6 x...

Page 61: ...2 90105 06213 BOLT M6 x 1 0 10 2 1 0 0 2 2 APPLY TO SCREW ROCKING APPLY OIL TO THE BEARING SURFACE ONLY CRANKCASE 1 x CRANKCASE 2 95812 06040 BOLT FLANGE M6 x 1 0 10 2 1 0 0 2 5 APPLY OIL TO BOTH SCRE...

Page 62: ...4H7 15189 00 PLUG M20 x 1 5 8 2 0 8 0 2 2 TAKE CARE NOT TO OVERTIGHTEN Install CLUTCH WIRE HOLDER 90110 06340 BOLT M6 x 1 0 10 2 1 0 0 2 2 APPLY TO SCREW ROCKING ACM LEAD 90110 06182 BOLT HEXAGON SOCK...

Page 63: ...CREW M6 x 1 0 10 2 1 0 0 2 2 APPLY TO SCREW ROCKING Install STOPPER SCREW 1D7 18127 00 STOPPER SCREW M8 x 1 25 22 2 2 2 0 2 1 APPLY TO SCREW ROCKING Install ARM SHIFT 90105 06127 BOLT FLANGE M6 x 1 0...

Page 64: ...2 APPLY TO SCREW ROCKING OIL PRESSURE SWITCH 1WS 82504 00 SW OIL PRESSURE PT1 8 12 5 2 1 25 0 2 1 When mended use 67F 82504 0 and apply the sealing agent to the thread part ThreeBond MEC 2403 Install...

Page 65: ...GON SOCKET M12 x 1 25 50 62 5 0 6 2 1 PROCEDURE TO INSTALL THE ENGINE FOR DETAILS SEE page 69 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...

Page 66: ...90109 12010 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 REA...

Page 67: ...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 F...

Page 68: ...65 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 69: ...ening of 45 N m 4 5 kgf m 4 In the following order 1 10 loosen each 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...

Page 70: ...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 6 8 7 5 2 4 3 1 22 32 40 12 23 33 13 24 34 14 25 35 1...

Page 71: ...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 se...

Page 72: ...en attach the bolt 7 temporarily 5 Tighten the two engine adjusting bolts 1 at specified torque Check that the bearing surface of the bolts 1 completely fit the surface of the engine 6 Tighten the two...

Page 73: ...3 Tighten the nut 3 self rocking at specified torque 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 s...

Page 74: ...71 4 Headlight Cord Wiring Diagram...

Page 75: ...72 5 YZF R1 Wiring Diagram...

Page 76: ......

Page 77: ...Published by YAMAHA MOTOR ENGINEERING co LTD...

Search results

Summary of Contents for YZF-R1

Reviews:

Related manuals for YZF-R1

Brands by name

Popular brands

Yamaha YZF-R1, Kit Manual

Search results

Summary of Contents for YZF-R1

Reviews:

Related manuals for YZF-R1

Brands by name

Popular brands