Yamaha YZF-R1SV Assembly Manual Download Page 1 | Manualshive

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Summary of Contents for YZF-R1SV

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Page 2: ...e procedures below are described in the order that the procedures are carried out correctly and com pletely Failure to do so can result in poor performance and possible harm to the vehicle and or rider Follow the instructions in the Dealer Warranty Handbook Procedure Section Particularly important information is distinguished in this manual by the following notations The Safety Alert Symbol means ...

Page 3: ...ance required 5 Install so that the arrow mark faces up ward 6 Apply motor oil 7 Made of rubber or plastics 8 A Ref No indicating the order of op erations B Part name C Quantity of parts per vehicle D Place where parts are held V Stored in plastic bag C Stored in carton box S Fixed inside the steel frame and or contained in the Styro foam tray upper or lower Temporarily installed or secured E Size...

Page 4: ... or shoes EAA00050 SYMBOLS USED ON CRATE CARTON 1 Contents of the transport package are fragile therefore the package must be handled with care 2 Indicates correct upright position of the transport package 3 Transport package must be kept away from rain 4 Do not step anywhere on this carton box 5 Up to 6 of the transport packages can be piled up 6 Insertion of the forklift arms from this side can ...

Page 5: ...move the carton box 2 3 Remove the packing frame bolts 3 and steering stem nut 4 4 Remove the packing frames 5 Lift up and then move to the side Remove the bolts while holding the frame Before starting the assembly check for damaged or missing parts Check both the parts contained in the carton boxes and on the vehicle for damage scratches and oth er defects ...

Page 6: ... 2 EAA00070 PARTS LOCATION 1 Carton box 2 Vinyl bag ...

Page 7: ...arton box 1 Screws special nuts and washers windshield 2 Collars 3 Nuts 4 Dampers 5 Plugs 6 Rear view mirrors 7 Windshield 8 Owner s manual 9 Owner s tool kit 2 2 Vinyl bag 1 Steering steem nut 2 Handlebar bolts 3 Keys ...

Page 8: ... 4 EAA00100 SETUP PROCEDURES Perform the setup procedures in the order indicated by the numbers Always follow the order as shown ...

Page 9: ...en the handlebar bolt Handlebar bolt 13 Nm 1 3 mSkg 9 4 ftSlb Proper throttle cables routing is essential to assure safe vehicle operation Refer to CABLE ROUTING EAA00202 2 HANDLEBAR left A Tighten the handlebar pinch bolt Handlebar pinch bolt 17 Nm 1 7 mSkg 12 ftSlb B Tighten the handlebar bolt Handlebar bolt 13 Nm 1 3 mSkg 9 4 ftSlb Proper cable routing is essen tial to assure safe vehicle opera...

Page 10: ... is not scratched A Tighten the nut to specification Screw 0 4 Nm 0 04 mSkg 0 3 ftSlb 5 REAR VIEW MIRRORS A Tighten the rear view mirrors nuts Rear view mirror nut 7 Nm 0 7 mSkg 5 1 ftSlb EAA00189 6 BATTERY A Installing the battery Refer to ADJUSTMENTS AND PREDELIVERY SERVICE B First connect the positive lead red lead to the positive termi nal C Second connect the negative lead black lead to the n...

Page 11: ...ad 4 Left handlebar switch lead 5 Brake hose 6 Throttle cable return side 7 Throttle cable pull side 8 Battery negative lead 9 Battery positive lead A Route the clutch cable so as to get along the front side of the main switch after passing it through the guide B Pass the main switch lead through the guide wire C Pass the left handlebar switch lead through the guide wire ...

Page 12: ... 8 EAA01100 ADJUSTMENTS AND PREDELIVERY SERVICE Perform the predelivery service in the order indicated by the letters Always follow the order as shown ...

Page 13: ...eld eyes when working near batteries KEEP OUT OF THE REACH OF CHIL DREN D If the voltage is lower than 12 8 V the battery must be charged If this is not done the life of the battery will be shortened drastically Refer to the service manual for battery charging instructions D Never remove the strip of caps nor add any water or electrolyte EAA01009 B CHECKING THE TIRE PRESSURE 1 Check D tire pressur...

Page 14: ... any chemical addi tives D Do not allow foreign materials to en ter the crankcase API Service SE SF and SG type or equivanlent e g SF SE SF SE CC SF SE SD 4 Start the engine warm it up for several minutes and then turn it off 5 Check the engine oil level again Before checking the engine oil level wait a few minutes until the oil has settled EAA01017 D CHECKING THE COOLANT LEVEL 1 Stand the vehicle...

Page 15: ...tle cable free play is decreased c Tighten the locknut After adjusting the throttle cable free play turn the handlebar to the right and to the left to ensure that this does not causethe engine idling speed to change EAA01023 G ADJUSTING THE FRONT BRAKE 1 Adjust D brake lever position distance a from the throttle grip to the brake lever a Turn the adjusting knob 1 until the brake lever is in the de...

Page 16: ...g the brake pedal position make sure that there is no brake drag EAA01032 I CHECKING THE BRAKE FLUID LEVEL 1 Stand the vehicle on a level surface D Place the vehicle on a suitable stand D Make sure that the vehicle is upright 2 Check D brake fluid level Below the minimum level mark a Add the recommended brake fluid to the proper level Recommended brake fluid DOT 4 A Front brake B Rear brake D Use ...

Page 17: ...stem is the following order 1 front brake master cylinder 2 front brake calipers 3 front brake master cylinder d Place the other end of the hose into a container e Slowly apply the brake several times f Fully squeeze the brake lever or fully de press the brake pedal and hold it in posi tion g Loosen the bleed screw This will release the tension and cause thebrake lever to contact the throttlegrip ...

Page 18: ... in direction a until it stop 1 If the alignment mark on the adjusting bolt is positioned past the alignment mark on the front fork cap turn the ad justing bolt in direction b until the align ment marks match Turn the adjusting bolt 3 complete turns in direction b and be sure the align ment marks match This is the standard position 2 If the alignment mark on the adjusting bolt is positioned before...

Page 19: ... go beyond the maximum or mini mum adjustment positions 1 Adjust D spring preload a Turn the adjusting knob 1 in direction a or b Direction a Spring preload is increased suspension is harder Direction b Spring preload is decreased suspension is softer Adjusting positions Standard 6 turns in direction b Minimum 0 turns in direction b Maximum 14 turns in direction b from the fully turned in directio...

Page 20: ...sting positions Standard 30 clicks in direction b Minimum 42 clicks in direction b Maximum 1 clicks in direction b from the fully turned in direction a D slow compression damping a Turn the adjusting screw 2 in direction a or b Direction a Compression damping is increased suspension is harder Direction b Compression damping is decreased suspension is softer Adjusting positions Standard 10 clicks i...

Page 21: ... bolts 3 in direction a or b until the specified drive chain slack is obtained Direction a Drive chain is tightened Direction b Drive chain is loosened D To maintain the proper wheel alignment adjust both sides evenly D Push the rear wheel forward to make sure that there is no clearance between the swingarm end plates and the ends of the swingarm c Tighten the wheel axle nut to specifica tion Whee...

Page 22: ...dlight beam moves to the right EAA00185 Q ADJUSTING THE DIGITAL CLOCK Turn the key to ON To change the display to the clock mode push the SELECT button 3 for at least one second To change the display back to the prior mode push the SELECT button 3 1 Adjust D digital clock 1 a Push the SELECT button 3 and RE SET button 2 together for at least two seconds b When the hour digits start flashing push t...

Page 23: ... 90 kg 198 lb load X Maximum load Front 250 kPa 2 5 kgf cm2 36 psi Rear 290 kPa 2 9 kgf cm2 42 psi High speed riding Front 250 kPa 2 5 kgf cm2 36 psi Rear 290 kPa 2 9 kgf cm2 42 psi Load is the total weight of cargo rider passenger and accessories EAA10100 STANDARD EQUIPMENT 1 Owner s manual 1 pc 2 Owner s tool kit 1 pc 3 Owner s tool kit 2 1 pc EAA10200 OWNER S TOOL KIT 1 Owner s tool bag 1 pc 2 ...

Page 24: ...and console panel M5 1 3 0 13 0 9 End grip and handlebar M6 4 0 4 2 9 Horn bracket and under bracket M6 7 0 7 5 1 Coolant reservoir tank and frame M6 5 0 5 3 6 Engine mount front left and right M10 45 4 5 33 Engine mount rear upper M10 51 5 1 37 Engine mount rear under M10 51 5 1 37 Engine mount rear adjust bolt M16 7 0 7 5 1 Catalyst pipe stay and frame M10 44 4 4 32 Clutch cable lock nut engine ...

Page 25: ...e pinch bolt M8 See NOTE 2 1 First tighten the ring nut to approximately 52 Nm 5 2 mSkg 38 ftSlb with a torque wrench then loosen the ring nut completely 2 Retighten the lower ring nut 18 Nm 1 8 mSkg 13 ftSlb 1 Insert the front wheel axle from the right side and tighten it with the flange bolt from the left side to 91 Nm 9 1 mSkg 65 8 ftSlb 2 In the order from the pinch bolt 2 pinch bolt 1 pinch b...

Page 26: ...PRINTED IN USA ...

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