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Yamaha YZF-R1LEVC, Supplementary Service Manual, Page: 50 / 87

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Yamaha YZF-R1LEVC Supplementary Service Manual Download Page 50

CHAS

42

EAS00656

CHECKING THE FRONT FORK LEGS

(YZF-R1LE)
The following procedure applies to both of the
front fork legs.
1. Check:

• inner tube 
• outer tube 

Bends/damage/scratches 

→

 Replace.

WARNING

Do not attempt to straighten a bent inner
tube as this may dangerously weaken it.

2. Measure:

• spring free length 

Out of specification 

→

 Replace.

3. Check:

• damper rod  

Damage/wear 

→

 Replace.

Obstruction 

→

 Blow out all of the oil pas-

sages with compressed air.

• damper rod adjusting rod

Bends/damage 

→

 Replace.

CAUTION:

• The front fork leg has a built-in damper

adjusting rod and a very sophisticated
internal construction, which are particu-
larly sensitive to foreign material.

• When disassembling and assembling the

front fork leg, do not allow any foreign
material to enter the front fork.

4. Check:

• cap bolt 

Damage 

→

 Replace.

• cap bolt O-ring 

Spring free length

260 mm (10.24 in)
<Limit> : 254.8 mm (10.03 in)

FRONT FORK

Summary of Contents for YZF-R1LEVC

Page 1: ...YZF R1V 5VY 28197 11 SUPPLEMENTARY SERVICE MANUAL LIT 11616 19 75 YZF R1VC YZF R1LEV YZF R1LEVC ...

Page 2: ......

Page 3: ...ha Motor Corporation U S A is expressly prohibited Printed in U S A LIT 11616 19 75 EAS00001 FOREWORD This Supplementary Service Manual has been prepared to introduce new service and data for the YZF R1V YZF R1VC YZF R1LEV YZF R1LEVC For complete service information procedures it is necessary to use this Supplementary Service Manual together with the following manual YZF R1S YZF R1SC SERVICE MANUA...

Page 4: ...nded to provide the customer with the most satisfaction from his vehicle and to conform to federal environmental quality objectives Yamaha Motor Company Ltd is continually striving to improve all of its models Modifications and significant changes in specifications or procedures will be forwarded to all authorized Yamaha deal ers and will appear in future editions of this manual where applicable N...

Page 5: ...top of each page except in Chapter 3 PERIODIC CHECKS AND ADJUSTMENTS where the sub section title s appears Sub section titles appear in smaller print than the section title To help identify parts and clarify procedure steps there are exploded diagrams at the start of each removal and disassembly section Numbers are given in the order of the jobs in the exploded diagram A circled number indicates a...

Page 6: ...dicate the following Serviceable with engine mounted Filling fluid Lubricant Special tool Tightening torque Wear limit clearance Engine speed Electrical data Symbols to in the exploded diagrams indicate the types of lubricants and lubrication points Engine oil Gear oil Molybdenum disulfide oil Wheel bearing grease Lithium soap based grease Molybdenum disulfide grease Symbols to in the exploded dia...

Page 7: ...GENERAL MAINTENANCE AND LUBRICATION CHART 27 CHASSIS 29 ADJUSTING THE FRONT FORK LEGS 29 ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY 32 CHASSIS FRONT WHEEL AND BRAKE DISCS 35 REAR WHEEL AND BRAKE DISCS 36 REAR BRAKE DISC AND REAR WHEEL SPROCKET 36 FRONT FORK 38 FRONT FORK LEGS 38 DISASSEMBLING THE FRONT FORK LEGS 40 CHECKING THE FRONT FORK LEGS 42 ASSEMBLING THE FRONT FORK LEGS 43 REAR SHOCK ABSORB...

Page 8: ...ICTION PLATES 67 CHECKING THE CLUTCH PLATES 68 CHECKING THE CLUTCH SPRINGS 69 CHECKING THE CLUTCH HOUSING 69 CHECKING THE PRESSUR PLATE 2 70 CHECKING THE CLUTCH BOSS 70 CHECKING THE PRESSURE PLATE 1 70 CHECKING THE PULL LEVER SHAFT AND PULL ROD 71 INSTALLING THE CLUTCH 71 YZF R1V YZF R1VC YZF R1LEV YZF R1LEVC 2006 WIRING DIAGRAM ...

Page 9: ... list provided below to avoid any mistakes NOTE For U S A and Canada use part number starting with YM YU or ACC For others use part number starting with 90890 YZF R1LE Tool No Tool name Function Illustration 90890 01472 Front fork cap bolt wrench This tool is used to loosen or tighten the front fork cap bolt 90890 01504 Damper rod holder This tool is used to loosening or tightening the damper rod ...

Page 10: ...Overall length 2 085 mm 82 1 in Wheelbase 1 415 mm 55 7 in Weight Wet with oil and a full fuel tank 194 kg 428 lb USA YZF R1 195 kg 430 lb CAL YZF R1 195 kg 430 lb USA YZF R1LE 195 kg 430 lb CAL YZF R1LE Maximum load except vehicle 201 kg 443 lb USA YZF R1 200 kg 441 lb CAL YZF R1 200 kg 441 lb USA YZF R1LE 200 kg 441 lb CAL YZF R1LE GENERAL SPECIFICATIONS ...

Page 11: ...7 in Clutch Friction plates Color code Red Thickness 2 9 3 1 mm 0 114 0 122 in 2 8 mm 0 110 in Plate quantity 7 Color code Red Thickness 2 9 3 1 mm 0 114 0 122 in 2 8 mm 0 110 in Plate quantity 1 Color code Red Thickness 2 9 3 1 mm 0 114 0 122 in 2 8 mm 0 110 in Plate quantity 1 Clutch plates Thickness 1 9 2 1 mm 0 07 0 08 in Plate quantity 8 Max warpage 0 1 mm 0 0039 in Clutch springs Free length...

Page 12: ... CAL YZF R1 90 200 kg 198 441 lb 250 kPa 2 5 kgf cm2 2 5 bar 35 6 psi USA YZF R1LE 90 200 kg 198 441 lb 250 kPa 2 5 kgf cm2 2 5 bar 35 6 psi CAL YZF R1LE Rear tire Model manufacturer Pilot POWER Pilot POWER G MICHELIN YZF R1 D218G DUNLOP YZF R1 DIABLO CORSA PIRELLI YZF R1LE Tire pressure cold 90 201 kg 198 443 lb 290 kPa 2 9 kgf cm2 2 9 bar 41 3 psi USA YZF R1 90 200 kg 198 441 lb 290 kPa 2 9 kgf ...

Page 13: ... 254 8 mm 10 03 in Coller length 42 mm 1 653 in Installed length 248 0 mm 9 76 in Spring rate K1 9 50 N mm 0 97 kg mm 54 22 lb in Fork oil Recommended oil Suspension oil Ohlins R T 43 ACC RT43F 00 00 Quantity each front fork leg 0 43 L 0 38 Imp qt 0 45 US qt Level from the top of the outer tube with the outer tube fully compressed and without the fork spring 145 mm 5 71 in Spring preload adjusting...

Page 14: ... 0 Standard 6 Maximum 20 Rebound damping adjusting positions Minimum 18 Standard 14 Maximum 1 Compression damping adjusting positions fast compression damping Minimum 42 Standard 30 Maximum 1 Compression damping adjusting positions slow compression damping Minimum 17 Standard 10 Maximum 1 from the fully turned in position Drive chain Model manufacturer 50VA8 DAIDO Link quantity 118 Drive chain sla...

Page 15: ...SA Ten hour rate amperage 0 9 A Item Fastener Thread size Q ty Tightening torque Remarks Nm m kg ft lb Exhaust pipe and exhaust valve pipe assembly Bolt M6 5 12 1 2 8 7 EXUP servo motor Bolt M6 2 6 0 6 4 3 Crankcase Bolt M6 10 10 1 0 7 2 Drive sprocket cover Bolt M6 2 12 1 2 8 7 Drive sprocket cover Bolt M6 1 12 1 2 8 7 Plate Bolt M6 2 12 1 2 8 7 ELECTRICAL SPECIFICATIONS TIGHTENING TORQUES ...

Page 16: ...h the flange bolt from the left side to 91 Nm 9 1 m kg 65 8 ft lb 2 In the order from the pinch bolt pinch bolt pinch bolt tighten each bolt to 26 Nm 2 6 m kg 19 ft lb without perform ing temporary tightening 3 Check that the end face of the axle head and the end face of the fork side are flush mounted If they are out of alignment make sure to fit them by adding the external force by hand or with ...

Page 17: ...INTS AND LUBRICANT TYPES ENGINE EAS00032 CHASSIS Lubrication point Lubricant Valve lifter surfaces intake and exhaust Valve stem ends intake and exhaust Lubrication point Lubricant Pivot shaft LUBRICATION POINTS AND LUBRICANT TYPES ...

Page 18: ...SPEC 10 LUBRICATION DIAGRAMS Main axle Oil delivery pipe Drive axle LUBRICATION DIAGRAMS ...

Page 19: ...ion of the ground terminal can be either top side or flip side Make sure to insert the coupler and boot to the stay 1 hole The speedometer lead should not be strained To the stay 1 hole Connect after passing over the upper side of the duct Clamp the head light lead by wrapping and insert it to the intake air grill hole only at the right side Do not connect the wire to the coupler with the plug for...

Page 20: ...d be no slack when clamping Point the tip of the clamp excessive part to the front side of the vehicle Fasten the head light lead with a clamp Feed a lead wire through the U shape cutout of the console panel CABLE ROUTING ...

Page 21: ...itch lead through the guide wire Point the tip of the band exces sive part to the left side of the vehicle and cut the surplus sec tion Clamp the section between 0 and 20 mm 0 and 0 79 in from the split of the under bracket Clamp the leads inside the front fork of the vehicle Point the exit of the horn lead to the left front fork side Route two throttle cables behind the brake hose pass between th...

Page 22: ...e caught between the wire guide and under bracket The throttle cable pull side should be positioned above the vehicle wen the wire guide is installed Clamp should be positioned at the protector lower end of the brake hose and wrapped on the protector Cut the tip leaving 2 to 4mm 0 08 0 16 in CABLE ROUTING ...

Page 23: ...ront side of the vehicle Fasten the right handlebar switch lead with a clamp To the wire harness The clutch cable positioning guide should be above the upper end of the clamp Fasten the clutch cable with a clamp Refer to Position relation between the clamp and guide Clamp the clamp upper end along the line of lower end of the hose clamp assembly Point the tip of the clamp excessive part to the fro...

Page 24: ...ingarm bracket and coolant reservoir tank Release the tip of the clamp and install it to the clutch cable Insert the clamp to the hole located on the right back side of the radiator Radiator fan motor lead should not be caught while inserting the clamp Push the clamp until it hits the radiator side stay Radiator fan motor lead should not be caught Clamp the clutch cable so that it is within this s...

Page 25: ...lamp excessive part to the down front side of the vehicle What the clamp fas tens at this stage are the han dlebar switch and main switch leads Pass the main switch lead and left handlebar switch lead between the frame and the heat protector To the coolant reservoir tank Fold back the clamp and secure it after passing the lead through the clamp To the EXUP servo motor Pass the coolant reservoir ta...

Page 26: ...mp The outside of the vehicle Inner most section of the vehi cle Can be routed in any order Route the water hose so that it is placed at the outermost position finally after routing other leads and hoses in the guide Route the coolant reservoir tank drain hose so that it is routed at the innermost position to each hose and lead Arrange so as not for each hose to cross in the part between BB from t...

Page 27: ...Sidestand switch lead Throttle body lead Coolant reservoir tank drain hose Fuel tank drain hose Cover 7 Radiator fan motor lead left Radiator fan motor lead right Wire harness Pipe 3 Frame Coolant reservoir tank hose Thermo stat assembly breather hose Throttle body side cap Mud guard Turn signal light lead License plate light lead Rear fender rib Speed sensor lead Rear brake light switch lead Rear...

Page 28: ...cle s upper side above the heat protector To the starter motor Fasten the wire harness clank shaft position sensor lead rear brake light switch lead and speed sensor lead with a clamp Then point the tip of the clamp cut the tip of the clamp leaving 2 to 4 mm 0 08 to 0 16 in to the inside of the vehicle Pass the water hose lower side of the thermostat and between the ground lead and the neutral swi...

Page 29: ...f leads However the coupler should be set in the rear frame so that it is not caught by the seat bottom cover and other components Point the tip of the clamp excessive part to the inside of the vehicle Fasten the wire har ness with a clamp Point the tip of the clamp sur plus section to the rear side of the vehicle Fasten the starter relay lead turn signal relay lead main fuse lead main fuse lead f...

Page 30: ...o lead and throt tle body lead with a clamp Point the tip of the clamp cut the tip of the clamp leaving 2 to 4 mm 0 08 to 0 16 in to the inside of the vehicle To the air filter To the throttle body To install the cover 7 install so as to set each coupler in the cover Make sure that each lead is not caught by the cover 7 Insert the wire harness wrap ping clamp to the hole of the frame Make sure tha...

Page 31: ...than the frame plate pass it to the inside of the vehicle from the hole Leads should be routed in random order Clamp can be inserted in any direction Route each lead lower than the frame plate Leads should be routed in random order Clamp can be inserted in any direction Route the leads in random order CABLE ROUTING ...

Page 32: ... specified in the drawing Install the part pointing the white paint part of the hose to the left side of the vehicle Point the clip grip to the left side of the vehicle Fuel piping connector attach ment directions fuel pump side Always use hands to connect disconnect the connec tor without using tool 1 Insert the connector until the click sound is heard and check that the connector does not come o...

Page 33: ...SPEC 25 2 After Item 1 mentioned above is finished check that the clamp is inserted from the down side and and sections are perfectly equipped CABLE ROUTING ...

Page 34: ...nt mark to the front side of the vehicle Point the clip grip to the upper side of the vehicle To the throttle body The knob of the clip can be positioned in any direction Install the part pointing the white paint mark to the left side of the vehicle Install the part pointing the yel low paint mark to the left side of the vehicle Point the clip grip to the down side of the vehicle Insert the hose s...

Page 35: ...r cracks or damage Replace if necessary 5 Fuel injection Check and adjust engine idle speed and syn chronization 6 Exhaust system Check for leakage Tighten if necessary Replace gasket s if necessary 7 Evaporative emission control system For California only Check control system for damage Replace if necessary 8 Air induction system Check the air cut off valve reed valve and hose for damage Replace ...

Page 36: ...500 mi 800 km and after washing the vehicle or riding in the rain 11 Steering bearings Check bearing assemblies for looseness Moderately repack with lithium soap based grease every 16 000 mi 2 5000 km or 24 months Repack 12 Steering damper Check operation and for oil leakage 13 Chassis fasteners Check all chassis fitting and fasteners Correct if necessary 14 Brake and clutch lever pivot shafts App...

Page 37: ...over Spring preload CAUTION Never go beyond the maximum or minimum adjustment positions 1 Adjust spring preload a Turn the adjusting bolt in direction or NOTE NOTE Be sure to align the alignment mark on the adjusting bolt with the alignment mark on the front fork cap Direction Spring preload is increased suspension is harder Direction Spring preload is decreased suspension is softer Adjusting posi...

Page 38: ...ark on the front fork cap turn the adjusting bolt in direction until the alignment marks match Turn the adjusting bolt 2 complete turns in direction and be sure the alignment mark match This is the standard position Rebound damping CAUTION Never go beyond the maximum or minimum adjustment positions 1 Adjust rebound damping a Turn the adjusting screw in direction or Direction Rebound damping is inc...

Page 39: ...ing screw in direction or Direction Compression damping is increased suspension is harder Direction Compression damping is decreased suspension is softer Adjusting positions Minimum 20 clicks in direction Standard 12 clicks in direction Maximum 1 clicks in direction with the adjusting screw fully turned in direction ADJUSTING THE FRONT FORK LEGS ...

Page 40: ... preload a Turn the adjusting knob in direction or Rebound damping CAUTION Never go beyond the maximum or minimum adjustment positions Direction Spring preload is increased suspension is harder Direction Spring preload is decreased suspension is softer Adjusting positions Minimum 0 turns in direction Standard 6 turns in direction Maximum 20 turns in direction with the adjusting knob fully turned i...

Page 41: ...und damping is decreased suspension is softer Adjusting positions Minimum 18 clicks in direction Standard 14 clicks in direction Maximum 1 clicks in direction with the adjusting screw fully turned in direction Direction Compression damping is increased suspension is harder Direction Compression damping is decreased suspension is softer Adjusting positions Minimum 42 clicks in direction Standard 30...

Page 42: ...e adjusting screw in direction or Direction Compression damping is increased suspension is harder Direction Compression damping is decreased suspension is softer Adjusting positions Minimum 17 clicks in direction Standard 10 clicks in direction Maximum 1 clicks in direction with the adjusting screw fully turned in direction ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY ...

Page 43: ...hose holder left and right 2 2 Front brake caliper left and right 2 3 Front wheel axle pinch bolt 4 4 Front wheel axle bolt 1 5 Front wheel axle 1 6 Collar left and right 2 7 Front wheel 1 8 Front brake disc left and right 2 For installation reverse the removal procedure 6 Nm 0 6 m kg 4 3 ft lb 91 Nm 9 1 m kg 66 ft lb 26 Nm 2 6 m kg 19 ft lb 6 Nm 0 6 m kg 4 3 ft lb 35 Nm 3 5 m kg 25 ft lb 23 Nm 2 ...

Page 44: ...d rear wheel sprocket Remove the parts in the order listed 1 Rear brake disc 1 2 Rear wheel sprocket 1 3 Collar 2 4 Oil seal 1 5 Bearing 1 6 Rear wheel drive hub 1 7 Rear wheel drive hub damper 5 8 Rear wheel 1 For installation reverse the disassembly procedure YZF R1LE 30 Nm 3 0 m kg 22 ft lb 100 Nm 10 m kg 72 ft lb REAR WHEEL AND BRAKE DISCS ...

Page 45: ...Part Q ty Remarks Disassembling the rear wheel Disassemble the parts in the order listed Collar 1 Bearing 1 Spacer 1 Oil seal 1 Bearing 1 For assembly reverse the disassembly procedure YZF R1LE REAR WHEEL AND BRAKE DISCS ...

Page 46: ...he order listed NOTE NOTE The following the procedure applies to both of the front fork legs Fork stay 1 Fork bracket 1 Cap bolt 1 O ring 1 Damper adjusting rod 1 Nut 1 Spring seat upper 1 Fork spring 1 Clip 1 Spacer 1 YZF R1LE 20 Nm 2 0 m kg 14 ft lb 25 Nm 2 5 m kg 18 ft lb 6 Nm 0 6 m kg 4 3 ft lb 48 Nm 4 8 m kg 35 ft lb FRONT FORK ...

Page 47: ...t 1 Dust seal 1 Oil seal clip 1 Oil seal 1 Washer 1 Damper rod assembly 1 Inner tube 1 Outer tube 1 For assembly reverse the disassembly procedure YZF R1LE 20 Nm 2 0 m kg 14 ft lb 25 Nm 2 5 m kg 18 ft lb 6 Nm 0 6 m kg 4 3 ft lb 48 Nm 4 8 m kg 35 ft lb FRONT FORK ...

Page 48: ...he fork spring compressor b Install the spanner between the nut and the spring seat upper c Loosen the nut d Remove the cap bolt e Remove the spanner and fork spring com pressor WARNING The fork spring is compressed 2 Remove nut spring seat upper fork spring clip spacer spring guide 3 Drain fork oil NOTE NOTE Stroke the damper rod several times while draining the fork oil Fork spring compressor 90...

Page 49: ...ng seat NOTE NOTE Use a wire or the like and bend the end in L letter shape for about 10 mm 0 39 in and hook this part to the spring seat end and pull out the spring seat 6 Remove damper rod assembly NOTE NOTE While holding the inner tube with the damper rod holder loosen the damper rod assem bly Damper rod holder 90890 01504 FRONT FORK ...

Page 50: ...damper rod Damage wear Replace Obstruction Blow out all of the oil pas sages with compressed air damper rod adjusting rod Bends damage Replace CAUTION The front fork leg has a built in damper adjusting rod and a very sophisticated internal construction which are particu larly sensitive to foreign material When disassembling and assembling the front fork leg do not allow any foreign material to ent...

Page 51: ...eg be sure to replace the following parts oil seal clip oil seal dust seal Before assembling the front fork leg make sure all of the components are clean 1 Install inner tube damper rod assembly 2 Tighten damper rod assembly LOCTITE NOTE NOTE While holding the inner tube with the damper rod holder tighten the damper rod assem bly 3 Lubricate inner tube s outer surface 48 Nm 4 8 m kg 35 ft lb Dampe...

Page 52: ...ased 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 oil seal during installation 5 Install Oil seal with the fork seal driver 6 Install oil seal clip NOTE NOTE Adjust the oil seal clip so that it fits into the outer tube s groove Fork seal driver 90890 01442 YM 01442 FRONT FORK ...

Page 53: ...fter filling slowly pump the front fork leg up and down to distribute the fork oil Fork seal driver 90890 01442 YM 01442 Rod puller 90890 01437 YM A8703 Rod puller attachment 90890 01435 YM A8703 Quantity each front fork leg 0 43 L 0 38 Imp qt 0 45 US qt Recommended oil Suspension oil Ohlins R T 43 ACC RT43F 00 00 Front fork leg oil level from the top of the outer tube with the outer tube fully co...

Page 54: ...nstall the nut e Remove the rod puller and adapter f Install the nut and position it as specified g Install the damper adjusting rod and cap bolt and then finger tighten the cap bolt until it stop NOTE NOTE Install the cap bolt with rebound damping screw fully loosened h Hold the cap bolt and tighten the nut to specification i Remove the fork spring compressor WARNING The fork spring is compressed...

Page 55: ...INGS in chapter 3 Protector muffler catalyst pipe assembly and EXUP servo motor Refer to EXHAUST PIPE in chapter 5 1 Self locking nut bolt 1 1 2 Self locking nut bolt 1 1 3 Self locking nut bolt 1 1 4 Self locking nut 1 5 Rear shock absorber assembly 1 6 Oil seal bearing collar 4 2 2 7 Collar self locking nut bolt 1 1 1 8 Connecting rod 1 9 Oil seal bearing collar 4 2 2 YZF R1LE 92 Nm 9 2 m kg 67 ...

Page 56: ...ob Part Q ty Remarks 10 Relay arm 1 For installation reverse the removal procedure YZF R1LE 92 Nm 9 2 m kg 67 ft lb 44 Nm 4 4 m kg 32 ft lb 44 Nm 4 4 m kg 32 ft lb 44 Nm 4 4 m kg 32 ft lb REAR SHOCK ABSORBER ASSEMBLY ...

Page 57: ...ttom cowling rear cowling upper Refer to COWLINGS in chapter 3 protector muffler catalyst pipe assembly EXUP servo motor Refer to EXHAUST PIPE in chapter 5 3 Remove connecting rod front bolt rear shock absorber assembly lower bolt relay arm to swingarm bolt NOTE NOTE While removing the rear shock absorber assembly lower bolt hold the swingarm so that it does not drop down 4 Remove rear shock absor...

Page 58: ...shock absorber assembly upper nut rear shock absorber assembly lower nut relay arm to swingarm nut connecting rod front nut 5 Install EXUP servo motor catalyst pipe assembly muffler protector Refer to EXHAUST PIPE in chapter 5 rear cowling upper bottom cowling Refer to COWLINGS in chapter 3 fuel tank Refer to FUEL TANK in chapter 3 rider seat and passenger seat Refer to SEATS in chapter 3 Recommen...

Page 59: ...mbly lower bolt hold the swingarm so that it does not drop down 3 Measure swingarm side play swingarm vertical movement a Measure the tightening torque of the pivot shaft nut b Measure the swingarm side play by moving the swingarm from side to side c If the swingarm side play is out of specifica tion check the spacers bearings washers and dust covers d Check the swingarm vertical movement by movin...

Page 60: ...t pivot shaft 3 Wash pivot shaft dust covers spacer washers bearings 4 Check dust covers spacer Damage wear Replace bearings Damage pitting Replace 5 Check connecting rod assembly Refer to CHECKING THE CONNECTING ROD ASSEMBLY relay arm Damage wear Replace 6 Check bearings oil seals Damage pitting Replace 7 Check collars Damage scratches Replace Recommended cleaning solvent Kerosene SWINGARM AND DR...

Page 61: ...ng rod 1 and con necting rod 2 fully to the connecting rod arm b Rotate the connecting rod 1 within one rotation so that the bearing is parallel At this time align the direction of bolt c Rotate the connecting rod arm to adjust the connecting rod assembly length to 206 mm 8 11 in d Tighten the connecting rod bolt temporarily e Attach the connecting rod assembly to the vehicle and tighten the conne...

Page 62: ...ive sprocket and rear drive sprocket as a set NOTE NOTE While measuring the 15 link section push down on the drive chain to increase its ten sion Perform this measurement at two or three dif ferent places 2 Check drive chain Stiffness Clean and lubricate or replace 3 Clean drive chain a Wipe the drive chain with a clean cloth b Put the drive chain in kerosene and remove any remaining dirt c Remove...

Page 63: ...ain 4 Check O rings Damage Replace the drive chain drive chain rollers Damage wear Replace the drive chain drive chain side plates Damage wear Replace the drive chain Cracks Replace the drive chain and make sure that the battery breather hose is properly routed away from the drive chain and below the swingarm 5 Lubricate drive chain 6 Check drive sprocket rear wheel sprocket More than 1 4 tooth we...

Page 64: ...ne mount collar inside YZF R1 1 Engine mount collar inside outside YZF R1LE 2 3 Engine mount collar outside YZF R1 1 Engine mount collar center YZF R1LE 1 4 Left front engine mounting bolt 1 5 Lower self locking nut 1 6 Lower engine mounting bolt 1 7 Upper self locking nut 1 51 Nm 5 1 m kg 37 ft lb 45 Nm 4 5 m kg 33 ft lb 51 Nm 5 1 m kg 37 ft lb 45 Nm 4 5 m kg 33 ft lb 7 Nm 0 7 m kg 5 1 ft lb YZF ...

Page 65: ...bolt 2 NOTE NOTE Use the pivot shaft wrench and adapter to loosen the engine mounting adjust bolts 10 Engine 1 For installation reverse the removal procedure 51 Nm 5 1 m kg 37 ft lb 45 Nm 4 5 m kg 33 ft lb 51 Nm 5 1 m kg 37 ft lb 45 Nm 4 5 m kg 33 ft lb 7 Nm 0 7 m kg 5 1 ft lb YZF R1LE ENGINE ...

Page 66: ...ith lithium soap based grease 4 Install left front engine mount bolt temporary tighten 5 Install engine mount collar inside engine mount collar outside right front engine mount bolt temporary tighten engine mount collar inside outside engine mount collar center YZF R1 YZF R1LE 6 Tighten engine mounting adjust bolts NOTE NOTE Use the pivot shaft wrench and pivot shaft wrench adapter to tighten the ...

Page 67: ...lf locking nut and then tighten the upper self locking nut 8 Tighten left front engine mounting bolt 9 Tighten right front engine mounting bolt Pivot shaft wrench 90890 01471 YM 01471 Pivot shaft wrench adapter 90890 01476 51 Nm 5 1 m kg 37 ft lb 45 Nm 4 5 m kg 33 ft lb 45 Nm 4 5 m kg 33 ft lb ENGINE ...

Page 68: ...oosen 2 Timing chain tensioner 1 3 Timing chain tensioner gasket 1 4 Intake camshaft cap 3 5 Dowel pin 6 6 Exhaust camshaft cap 3 7 Dowel pin 6 Refer to REMOVING THE CAMSHAFTS 8 Intake camshaft 1 9 Exhaust camshaft 1 10 Camshaft sprocket 2 For installation reverse the removal procedure 10 Nm 1 0 m kg 7 2 ft lb 10 Nm 1 0 m kg 7 2 ft lb 24 Nm 2 4m kg 17 ft lb 24 Nm 2 4 m kg 17 ft lb 10 Nm 1 0 m kg 7...

Page 69: ...ide cover Right frame side panel Bottom cowling Engine oil Drain Refer to CHANGING THE ENGINE OIL in chapter 3 1 Cover 1 2 Clutch cable 1 Disconnect 3 Clutch cover 1 4 Clutch cover gasket 1 5 Dowel pin 2 6 Oil filler cap 1 For installation reverse the removal procedure 12 Nm 1 2 m kg 8 7 ft lb 10 Nm 1 0 m kg 7 2 ft lb 12 Nm 1 2 m kg 8 7 ft lb CLUTCH ...

Page 70: ... Compression spring 6 2 Pressure plate 1 3 Pull rod 1 4 Bearing 1 5 Friction plate 1 1 6 Clutch plate 1 7 7 Friction plate 2 7 8 Wire clip 1 9 Clutch plate 2 1 10 Friction plate 3 1 11 Clutch damper spring 1 12 Clutch damper spring seat 1 95 Nm 9 5 m kg 69 ft lb YZF R1 10 Nm 1 0 m kg 7 2 ft lb CLUTCH ...

Page 71: ...s 13 Clutch boss nut 1 14 Washer 1 15 Thrust plate 1 1 16 Clutch boss 1 17 Thrust plate 2 1 18 Clutch housing 1 19 Bearing 1 For installation reverse the removal procedure 95 Nm 9 5 m kg 69 ft lb YZF R1 10 Nm 1 0 m kg 7 2 ft lb CLUTCH ...

Page 72: ...g 6 2 Pressure plate 1 1 3 Pull rod 1 4 Bearing 1 5 Friction plate 1 1 6 Clutch plate 1 1 7 Friction plate 2 7 8 Clutch plate 2 1 9 Clutch plate 3 6 10 Friction plate 3 1 11 Clutch damper spring 1 12 Clutch damper spring seat 1 13 Clutch boss nut 1 10 Nm 1 0 m kg 7 2 ft lb 95 Nm 9 5 m kg 69 ft lb YZF R1LE CLUTCH ...

Page 73: ...Spring 3 15 Clutch boss 1 16 Pressure plate 2 1 17 Conical spring washer 1 18 Thrust plate 2 1 19 Clutch housing 1 20 Bearing 1 For installation reverse the removal procedure 10 Nm 1 0 m kg 7 2 ft lb 95 Nm 9 5 m kg 69 ft lb YZF R1LE CLUTCH ...

Page 74: ...cross pattern After all of the bolts are fully loosened remove them 2 Remove compression spring bolts compression springs pressure plate pull rod 3 Remove friction plate 1 4 Remove clutch plate 1 friction plate 2 clutch plate 2 clutch plate 3 friction plate 3 clutch damper spring clutch damper spring seat 5 Straighten the clutch boss nut rib CLUTCH ...

Page 75: ... CHECKING THE FRICTION PLATES YZF R1LE The following procedure applies to all of the friction plates 1 Check friction plate Damage wear Replace the friction plates as a set 2 Measure friction plate thickness Out of specification Replace the friction plates as a set NOTE NOTE Measure the friction plate at four places Universal clutch holder 90890 04086 YM 91042 Friction plate thickness 2 9 3 1 mm 0...

Page 76: ... friction plates and clutch plates Out of specification Adjust NOTE NOTE Perform the thickness measurement without applying the oil a Assembly width adjusted by clutch plate and b Select the clutch plate from the following table Clutch plate Clutch plate Clutch plate warpage limit 0 1 mm 0 0039 in Assembly width 42 4 43 0 mm 1 67 1 69 in Part No Thickness 4B1 16324 00 1 6 mm 0 062 in 5VY 16325 00 ...

Page 77: ...1 Check clutch spring Damage Replace the clutch springs as a set 2 Measure clutch spring free length Out of specification Replace the clutch springs as a set EAS00284 CHECKING THE CLUTCH HOUSING YZF R1LE 1 Check clutch housing dogs Damage pitting wear Deburr the clutch housing dogs or replace the clutch housing NOTE NOTE Pitting on the clutch housing dogs will cause erratic clutch operation 2 Chec...

Page 78: ...F R1LE 1 Check clutch boss splines Damage pitting wear Replace the clutch boss NOTE NOTE Pitting on the clutch boss splines will cause erratic clutch operation 2 Check clutch boss Cracks damage Replace EAS00286 CHECKING THE PRESSURE PLATE 1 YZF R1LE 1 Check pressure plate Cracks damage Replace bearing Damage wear Replace CLUTCH ...

Page 79: ...on gear as a set 2 Check pull rod bearing Damage wear Replace INSTALLING THE CLUTCH YZF R1LE 1 Install clutch housing conical spring washer thrust plate 2 NOTE NOTE Align the projection of clutch housing and hollow of the oil pump drive gear 2 Install pressure plate 2 clutch boss NOTE NOTE Fit the groove of the pressure plate 2 to the projection of the clutch boss to assemble CLUTCH ...

Page 80: ...he clutch boss nut Lock the threads on the clutch boss nut by staking them with a drift punch at the point aligned with the groove in the axle 4 Install clutch damper spring seat clutch damper spring NOTE NOTE Install the clutch damper spring as shown in the illustration 5 Lubricate friction plates clutch plates with the recommended lubricant 95 Nm 9 5 m kg 69 ft lb Universal clutch holder 90890 0...

Page 81: ...rder 7 Install friction plate 1 NOTE NOTE Install the last friction plate shifting half phase 8 Install bearing pull rod pressure plate 1 NOTE NOTE Align the punch mark on the pressure plate with the punch mark on the clutch boss 9 Install clutch springs clutch spring bolts NOTE NOTE Tighten the clutch spring bolts in stages and in a crisscross pattern 10 Nm 1 0 m kg 7 2 ft lb CLUTCH ...

Page 82: ... onto the pull rod When installing the clutch cover push the pull lever and check that the punch mark on the pull lever aligns with the mark on the clutch cover Make sure that the pull rod teeth and pull lever shaft pinion gear are engaged 12 Tighten clutch cover bolts clutch cover bolt LOCTITE NOTE NOTE Tighten the clutch cover bolts in a stages and in a crisscross pattern 13 Adjust clutch cable ...

Page 83: ...h Start switch Turn signal relay Left handlebar switch Dimmer switch Horn switch Clutch switch Turn signal switch Horn Front turn signal position light left Front turn signal position light right Rear turn signal light left Rear turn signal light right Headlight Auxiliary light License plate light Rear brake light switch Tail brake light Headlight relay on off Headlight relay dimmer Fuse ignition ...

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