Table Of Contents - Yamaha R1 Series 2015 Service Manual

Table of Contents

How To Use This Manual5
Symbols6
Table Of Contents7
General Information9
Vehicle Identification Number10
Model Label10
Features11
Vehicle View11
Outline Of The Fi System11
Fi System12
Ycc-T (Yamaha Chip Controlled Throttle)14
Ycc-I (Yamaha Chip Controlled Intake)14
Ycc-T/Ycc-I System Outline16
Electronic Control-Related Features17
Digital Instrument Panel With Tft Liquid Crystal Display17
6-Axis "IMU" for 3-Dimensional Detection of Machine Motion18
Five Control Systems to Bring out the Machine's High Potential18
New Traction Control System (Tcs)19
Slide Control System (Scs)19
Lift Control System (Lif)19
Launch Control System (Lcs)19
Systems To Control Machine Motion Characteristics20
Quick Shift System (Qss) For Smooth Up-Shifting Even At Full Throttle20
Electronic Racing Suspension (Ers)20
First Abs And Unified Brake System On A Yamaha Supersport Model20
Pwr For Power Mode Selection And Yamaha Ride Control Adopted21
Rider-Machine Interface: Communication Control Unit (Ccu) Adopted21
Outline Of The Ubs22
Ubs Diagram24
Ubs Hydraulic Pressure Map25
Outline Of The Abs26
Abs Layout27
Brake Force And Vehicle Stability28
Wheel Slip And Hydraulic Control28
Abs Operation And Vehicle Control29
Electronic Abs Features30
Abs Component Functions31
Abs Block Diagram31
Wheel Sensors And Wheel Sensor Rotors31
Abs Warning Light32
Hydraulic Unit Assembly33
Hydraulic Control Valve33
Abs Ecu34
Abs Control Operation34
Ubs And Abs Operation35
Normal Braking (Abs Not Activated And Ubs Not Activated)35
Emergency Braking (Abs Activated And Ubs Not Activated)36
Ubs (Abs Not Activated And Ubs Activated)37
Ubs (Abs Activated And Ubs Activated)38
Abs Warning Light And Operation39
Abs And Ubs Function40
Glossary41
Display41
Speedometer41
Tachometer42
Information Display42
Yrc Items Lcs/Qs/Lif43
Gps Indicator43
Ers Indicator (Yzf-R1M)43
Error Mode44
Menu Screen45
Pwr46
Lcs47
Qss47
Lif47
Ers (Yzf-R1M)48
"Lap Time"49
"Logging" (for CCU-Equipped Models)50
"Maintenance"50
"Unit"50
"Shift Indicator"52
"Shift IND Brightness"52
"Tach IND Setting"53
"Peak Rev IND Setting"54
"Display Setting"54
"Clock"56
"All Reset"56
Preparation For Removal And Disassembly57
Replacement Parts57
Gaskets, Oil Seals And O-Rings57
Aluminium Bolts57
Important Information57
Lock Washers/Plates And Cotter Pins58
Bearings And Oil Seals58
Circlips58
Rubber Parts58
Basic Service Information59
Quick Fasteners59
Electrical System60
Electrical Parts Handling60
Checking The Electrical System62
Checking The Connections62
Special Tools65
Specifications75
General Specifications76
Engine Specifications77
Chassis Specifications82
Electrical Specifications86
Tightening Torques89
General Tightening Torque Specifications89
Engine Tightening Torques90
Chassis Tightening Torques97
Lubrication Points And Lubricant Types102
Engine102
Chassis103
Lubrication System Chart And Diagrams106
Engine Oil Lubrication Chart106
Lubrication Diagrams108
Cooling System Diagrams122
Cable Routing126
Periodic Checks And Adjustments173
Periodic Maintenance Chart For The Emission Control System175
General Maintenance And Lubrication Chart175
Introduction175
Checking The Spark Plugs178
Checking The Fuel Line (Primary Injector)178
Checking The Fuel Line (Secondary Injector)178
Adjusting The Valve Clearance179
Checking The Engine Idling Speed183
Synchronizing The Throttle Bodies183
Checking The Throttle Body Synchronization183
Adjusting The Throttle Body Synchronization184
Checking The Throttle Body Joints185
Checking The Crankcase Breather Hose185
Checking The Exhaust System185
Adjusting The Exhaust Gas Volume186
Replacing The Air Filter Element186
Checking The Air Induction System186
Adjusting The Clutch Lever Free Play187
Checking The Brake Operation188
Checking The Brake Fluid Level188
Adjusting The Front Disc Brake188
Checking The Front Brake Pads189
Adjusting The Rear Disc Brake189
Checking The Rear Brake Pads189
Checking The Front Brake Hoses190
Checking The Rear Brake Hose190
Bleeding The Hydraulic Brake System (Abs)190
Checking The Wheels191
Checking The Tires191
Checking The Wheel Bearings193
Checking The Swingaram Operation193
Lubricating The Swingarm Pivot193
Adjusting The Drive Chain Slack193
Lubricating The Drive Chain194
Checking And Adjusting The Steering Head195
Checking The Front Fork196
Lubricating The Steering Head196
Checking The Steering Damper196
Checking The Chassis Fasteners196
Lubricating The Brake Lever196
Lubricating The Clutch Lever196
Lubricating The Pedal196
Lubricating The Sidestand196
Checking The Sidestand Switch196
Adjusting The Front Fork Legs (For Yzf-R1)197
Compression Damping198
Adjusting The Preload Of The Front Fork Legs (For Yzf-R1M)198
Adjusting The Damping Force Of The Front Fork Legs199
Adjusting The Damping Force Of The Rear Shock Absorber199
Adjusting The Rear Shock Absorber Assembly200
Rebound Damping201
Adjusting The Preload Of The Rear Shock Absorber Assembly202
Checking The Engine Oil Level203
Changing The Engine Oil204
Measuring The Engine Oil Pressure205
Checking The Coolant Level206
Checking The Cooling System206
Changing The Coolant207
Cooling System208
Adjusting The Exup Cables209
Adjusting The Rear Brake Light Switch210
Checking And Lubricating The Cables210
Checking The Throttle Grip210
Adjusting The Headlight Beams212
Disassembling The Mudguard Assembly220
Removing The Electrical Components Tray229
Installing The Front Side Cowlings230
Removing The Front Side Cowlings (For Yzf-R1)230
Removing The Front Side Cowlings (For Yzf-R1M)230
Removing The Front Panels231
Installing The Front Side Cowlings (For Yzf-R1)231
Installing The Front Side Cowlings (For Yzf-R1M)231
Removing The Side Cover (Left)232
Installing The Side Cover (Left)232
Removing The Ecu (Engine Control Unit)233
Installing The Ecu (Engine Control Unit)233
General Chassis (3)234
Removing The Front Cowling Assembly235
Disassembling The Front Cowling Assembly236
Removing The Air Intake Duct237
Removing The Windshield Assembly238
Installing The Windshield Assembly238
Checking The Air Intake Duct Valve239
Checking The Vacuum Line239
Installing The Air Intake Duct Valve240
Front Wheel241
Removing The Front Wheel And Brake Discs242
Disassembling The Front Wheel243
Removing The Front Wheel244
Checking The Front Wheel244
Assembling The Front Wheel245
Maintenance Of The Front Wheel Sensor And Sensor Rotor246
Adjusting The Front Wheel Static Balance247
Installing The Front Wheel (Disc Brake)248
Rear Wheel Removal251
Removing The Brake Disc And Rear Wheel Sprocket252
Disassembling The Rear Wheel253
Removing The Rear Wheel254
Checking The Rear Wheel Drive Hub255
Checking And Replacing The Rear Wheel Sprocket255
Assembling The Rear Wheel256
Maintenance Of The Rear Wheel Sensor And Sensor Rotor257
Adjusting The Rear Wheel Static Balance257
Installing The Rear Wheel (Disc Brake)257
Front Brake260
Removing The Front Brake Pads260
Removing The Front Brake Master Cylinder261
Disassembling The Front Brake Master Cylinder262
Removing The Front Brake Calipers263
Disassembling The Front Brake Calipers264
Checking The Front Brake Discs265
Replacing The Front Brake Pads266
Checking The Front Brake Calipers268
Assembling The Front Brake Calipers268
Installing The Front Brake Calipers269
Checking The Front Brake Master Cylinder270
Assembling The Front Brake Master Cylinder270
Installing The Front Brake Master Cylinder270
Rear Brake272
Removing The Rear Brake Pads272
Removing The Rear Brake Master Cylinder273
Removing The Rear Brake Caliper274
Disassembling The Rear Brake Caliper275
Checking The Rear Brake Disc276
Replacing The Rear Brake Disc276
Checking The Rear Brake Caliper278
Assembling The Rear Brake Caliper279
Installing The Rear Brake Caliper279
Checking The Rear Brake Master Cylinder280
The Rear Brake Master Cylinder Installation281
Abs (Anti-Lock Brake System)282
Removing The Hydraulic Unit Assembly282
Abs Components Chart284
Checking The Hydraulic Unit Assembly286
Checking The Brake Pipes286
Installing The Hydraulic Unit Assembly286
Hydraulic Unit Operation Test287
Abs Reaction-Force Confirmation289
Checking The Abs Warning Light290
Handlebars291
Removing The Handlebars292
Checking The Handlebars293
Installing The Handlebars293
Removing The Front Fork Legs296
Front Fork (For Yzf-R1)296
Disassembling The Front Fork Legs297
Removing The Front Fork Legs (For Yzf-R1)298
Disassembling The Front Fork Legs (For Yzf-R1)298
Checking The Front Fork Legs (For Yzf-R1)300
Assembling The Front Fork Legs (For Yzf-R1)300
Installing The Front Fork Legs (For Yzf-R1)304
Front Fork (For Yzf-R1M)307
Removing The Front Fork Legs (For Yzf-R1M)309
Disassembling The Front Fork Legs (For Yzf-R1M)309
Checking The Front Fork Legs (For Yzf-R1M)310
Assembling The Front Fork Legs (For Yzf-R1M)311
Installing The Front Fork Legs (For Yzf-R1M)314
Steering Head317
Removing The Lower Bracket317
Checking The Steering Head319
Installing The Steering Head320
Rear Shock Absorber Assembly Removal321
Disposing Of A Rear Shock Absorber325
Removing The Rear Shock Absorber Assembly325
Disassembling The Rear Shock Absorber Assembly326
Checking The Rear Shock Absorber Assembly326
Checking The Connecting Arm And Relay Arm326
Assembling The Rear Shock Absorber Assembly327
Installing The Relay Arm327
Installing The Rear Shock Absorber Assembly328
Removing The Swingarm329
Checking The Swingram330
Installing The Swingram331
Removing The Drive Chain333
Checking The Drive Chain334
Checking The Rear Wheel Sprocket335
Installing The Drive Chain336
Adjusting The Shift Pedal337
Engine Inspection342
Measure The Compression Pressure342
Engine Removal344
Removing The Muffler And Exhaust Pipe344
Disconnecting The Leads And Hoses346
Installing The Engine348
Removing The Engine348
Installing The Exhaust Pipe And Muffler349
Camshafts350
Removing The Cylinder Head Cover350
Removing The Camshafts351
Removing The Timing Chain And Timing Chain Guide352
Removing The Rocker Arms353
Removing The Rocker Arms And Rocker Arm Shafts355
Checking The Camshafts355
Checking The Rocker Arms And Rocker Arm Shafts357
Checking The Timing Chain And Camshaft Sprocket357
Checking The Timing Chain Guides358
Checking The Timing Chain Tensioner358
Assembling The Timing Chain Cover359
Installing The Rocker Arms And Rocker Arm Shafts359
Installing The Timing Chain Cover359
Installing The Camshafts360
Removing The Cylinder Head364
Installing The Cylinder Head365
Removing The Valves And Valve Springs367
Checking The Valves And Valve Guides369
Valves And Valve Springs369
Removing The Valves369
Checking The Valve Seats371
Checking The Valve Spring Seat373
Installing The Valves374
Generator376
Removing The Stator Coil And Generator Rotor376
Installing The Generator377
Removing The Generator377
Removing The Starter Clutch379
Checking The Starter Clutch380
Installing The Starter Clutch380
Electric Starter382
Removing The Starter Motor382
Disassembling The Starter Motor383
Checking The Starter Motor384
Assembling The Starter Motor385
Removing The Oil Pan And Oil Pump386
Disassembling The Oil Pump388
Removing The Oil Pan389
Checking The Sprocket And Chain389
Checking The Oil Pump390
Checking The Relief Valve390
Checking The Oil Delivery Pipes391
Checking The Oil Strainer391
Assembling The Oil Pump391
Installing The Oil Pump391
Installing The Oil Pan393
Clutch394
Removing The Clutch Cover394
Removing The Pull Lever Shaft395
Removing The Clutch396
Checking The Friction Plates398
Checking The Clutch Plates398
Checking The Clutch Springs399
Checking The Clutch Housing399
Checking The Clutch Boss399
Checking The Pressure Plate399
Checking The Primary Drive Gear400
Checking The Primary Driven Gear400
Checking The Pull Lever Shaft And Pull Rod400
Installing The Clutch400
Shift Shaft403
Removing The Shift Shaft And Stopper Lever403
Checking The Shift Shaft404
Checking The Stopper Lever404
Installing The Shift Shaft404
Crankcase405
Removing The Crankcase Breather Cover And Switches405
Separating The Crankcase407
Disassembling The Crankcase408
Checking The Crankcase408
Assembling The Crankcase408
Installing The Crankcase Breather Cover410
Installing The Oil Pressure Switch410
Installing The Gear Position Sensor411
Removing The Connecting Rods And Pistons412
Connecting Rods And Pistons413
Checking The Cylinder And Piston414
Checking The Piston Rings415
Checking The Piston Pin416
Checking The Connecting Rods417
Installing The Connection Rod And Piston419
Removing The Crankshaft And Balancer Shaft425
Checking The Oil Nozzles426
Checking The Crankshaft426
Crankshaft And Balancer Shaft426
Checking The Balancer Shaft428
Installing The Crankshaft429
Installing The Balancer Assembly430
Transmission431
Removing The Transmission, Shift Drum Assembly, And Shift Forks431
Disassembling The Main Axle Assembly432
Removing The Transmission435
Checking The Shift Forks435
Checking The Shift Drum Assembly436
Checking The Transmission436
Assembling The Main Axle And Drive Axle436
Installing The Transmission437
Removing The Radiator440
Checking The Radiator441
Installing The Radiator442
Removing The Oil Cooler443
Checking The Oil Cooler444
Installing The Oil Cooler444
Removing The Thermostat445
Removing The Thermostat Assembly446
Checking The Thermostat446
Assembling The Thermostat Assembly446
Installing The Thermostat Assembly446
Removing The Water Pump448
Disassembling The Water Pump449
Checking The Water Pump450
Assembling The Water Pump450
Installing The Water Pump451
Fuel System453
Removing The Fuel Tank454
Removing The Fuel Pump455
Checking The Fuel Pump Operation455
Installing The Fuel Pump456
Installing The Fuel Tank456
Air Filter Case457
Removing The Air Filter Case And Secondary Injectors457
Removing The Air Filter Case458
Checking The Secondary Injectors (Before Removing)458
Removing The Fuel Hose (Primary Injector Joint Side And Secondary Injector Joint Side)458
Checking The Secondary Injectors458
Removing The Intake Funnel Assembly459
Checking The Air Filter Case Seal459
Checking The Intake Funnel459
Installing The Intake Funnel And Air Filter Case460
Checking The Intake Funnel Operation460
Installing The Secondary Injectors460
Installing The Air Filter Case Cover461
Installing The Fuel Hose (Primary Injector Joint Side And Secondary Injector Joint Side)461
Removing The Throttle Bodies462
Removing The Sensors464
Checking And Cleaning The Throttle Bodies465
Checking The Primary Injectors (Before Removing)465
Replacing The Throttle Bodies467
Installing The Primary Injectors467
Checking The Injector Pressure467
Checking The Fuel Pressure468
Adjusting The Throttle Position Sensor469
Adjusting The Accelerator Position Sensor470
Air Induction System472
Removing The Air Cut-Off Valve Assembly And Reed Valves474
Installing The Air Induction System477
Ignition System Circuit Diagram482
Engine Stopping Due To Sidestand Operation486
Ignition System Troubleshooting487
Electric Starting System Circuit Diagram490
Starting Circuit Cut-Off System Operation494
Electric Starting System Troubleshooting495
Charging System Circuit Diagram498
Charging System Troubleshooting502
Lighting System Circuit Diagram504
Lighting System Troubleshooting508
Signaling System Circuit Diagram510
Signaling System Troubleshooting514
Cooling System Circuit Diagram520
Cooling System Troubleshooting524
Fuel Injection System Circuit Diagram526
Ecu Self-Diagnostic Function530
Checking The Engine Trouble And System Warning Light530
Troubleshooting Method (Ecu)531
Ecu Detects An Abnormal Signal From A Sensor531
Yamaha Diagnostic Tool533
Troubleshooting Details (Ecu)535
Gear Position Sensor: Open Or Short Circuit Detected535
Cylinder Identification Sensor: No Normal Signals Received536
Intake Air Pressure Sensor: Open Or Short Circuit Detected539
Intake Air Pressure Sensor: Hose System Malfunction540
Throttle Position Sensor: Open Or Short Circuit Detected541
Exup Servo Motor: Open Or Short Circuit Detected542
Exup Servo Motor: Stuck Exup Servo Motor Is Detected543
Sidestand Switch: Break/Disconnection Of Blue/Yellow Lead Of The Ecu544
Intake Air Pressure Sensor Or Atmospheric Pressure Sensor545
Coolant Temperature Sensor: Open Or Short Circuit Detected547
Intake Air Temperature Sensor: Open Or Short Circuit Detected548
Atmospheric Pressure Sensor: Open Or Short Circuit Detected549
O2 Sensor 1: No Normal Signals Are Received From The O2 Sensor 1552
Latch Up Detected552
Cylinder-#1 Ignition Coil553
Cylinder-#2 Ignition Coil554
Cylinder-#3 Ignition Coil555
Cylinder-#4 Ignition Coil556
Primary Injector: Open Or Short Circuit Detected558
Secondary Injector: Open Or Short Circuit Detected559
Imu (Inertial Measurement Unit): No Normal Signals Are Received561
Rear Wheel Sensor: No Normal Signals Are Received562
Neutral Switch: Open Or Short Circuit Is Detected563
Clutch Switch: Open Or Short Circuit Is Detected563
Fuel System Voltage: Incorrect Voltage Supplied To The Fuel Injector569
Eeprom Fault Code Number: An Error Is Detected570
Malfunction In Ecu Internal Circuit572
Charging Voltage Is Abnormal573
Faulty Ecu Memory574
Accelerator Position Sensor: Open Or Short Circuit Detected574
Ycc-T Drive System: Malfunction Detected575
Steering Damper Solenoid: Open Or Short Circuit Detected577
O2 Sensor 1: No Normal Signals Are Received From The O2 Sensor 2578
No Normal Signals Are Received From The Front Front Wheel Sensor579
Signals Cannot Be Transmitted Between The Ecu And Multi-Function Meter581
The Ecu Cannot Receive Fault Signals From The Imu582
No Signal Exchange Between Ecu And Imu583
Fuel Pump System Circuit Diagram584
Fuel Pump System Troubleshooting588
Immobilizer System Circuit Diagram590
Immobilizer System - General Information594
Code Re-Registering Key Registration595
Standard Key Registration596
Voiding The Standard Key Code596
Immobilizer System Troubleshooting598
Immobilizer System Indicator Light Fault Code Indication599
Abs (Anti-Lock Brake System) Circuit Diagram600
Abs Coupler Location Chart606
Maintenance Of The Abs Ecu608
Abs Troubleshooting608
Abs Operation When The Abs Warning Light Comes On608
Abs Ecu Self-Diagnosis And Servicing608
Abs (Anti-Lock Brake System) - Fault Code Table614
Front Wheel Sensor (Intermittent Pulses Or No Pulses)614
Rear Wheel Sensor (Intermittent Pulses Or No Pulses)614
Front Wheel Sensor (Abnormal Pulse Period)615
Rear Wheel Sensor (Abnormal Pulse Period)615
Front Wheel Sensor (Open Or Short Circuit)615
Hydraulic Unit Assembly (Defective Abs Solenoid Power Circuit)615
Front Wheel Abs (Intermittent Wheel Speed Pulses)616
Front Wheel Sensor (Missing Pulses)616
Rear Wheel Sensor (Missing Pulses)616
Voltage Of Abs Ecu Power Supply Is High616
Abs (Anti-Lock Brake System) Final Check632
Electronically Adjustable Suspension System634
Maintenance Of The Scu (Suspension Control Unit)636
Scu (Suspension Control Unit) Self-Diagnostic Function636
Scu Troubleshooting Method636
Scu Detects An Abnormal Signal From A Sensor636
The Engine Trouble And System Warning Light Comes On637
Scu Troubleshooting Details637
Electrical Components654
Checking The Switches658
Checking The Fuses661
Replacing The Ecu (Engine Control Unit)661
Checking And Charging The Battery662
Checking The Relays665
Checking The Ignition Coils667
Checking The Ignition Spark Gap667
Checking The Crankshaft Position Sensor668
Checking The Starter Motor Operation668
Checking The Stator Coil668
Checking The Rectifier/Regulator669
Checking The Horn670
Checking The Fuel Sender670
Checking The Fuel Level Warning Light671
Checking The Radiator Fan Motors671
Checking The Coolant Temperature Sensor671
Checking The Throttle Position Sensor672
Checking The Accelerator Position Sensor672
Checking The Throttle Servo Motor673
Checking The Air Induction System Solenoid673
Checking The Atmospheric Pressure Sensor674
Checking The Cylinder Identification Sensor674
Checking The Intake Air Pressure Sensor675
Checking The Intake Air Temperature Sensor675
Checking The Intake Solenoid676
Checking The Steering Damper Solenoid676
Checking The Fuel Injectors677
Checking The Wheel Switch677
Troubleshooting679
Self-Diagnostic Function And Diagnostic Code Table (Ecu)684
Communication Error With The Meter685
Diagnostic Code: Sensor Operation Table686
Diagnostic Code: Actuator Operation Table689
Event Code Table692
Wiring Diagram Items695
Wiring Diagram701