Yamaha GYTR YZF-R1 Manual
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Yamaha GYTR YZF-R1 Manual

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Summary of Contents for Yamaha GYTR YZF-R1

  • Page 2 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.

  • Page 3: Table Of Contents

    CONTENTS 1 Engine Specifications ................. 1 2 Kit Parts ......................2 2-1 Installing Electrical Parts ................2 ECU Set (B3L-8591A-70) ...................2 Cable Interface (2CR-8533A-70) ................4 Wire Harness Set (B3L-F2590-70) ..............6 Wire, Sub-Lead (2KS-82509-70) ................ 7 Headlight Harness Set (BX4-F4350-71) ............18 Repair set ......................

  • Page 4: Engine Specifications

    Engine Specifications Spec SBK/JSB Displacement 998cm 998cm 998cm Bore/Stroke 79.0 × 50.9 mm 79.0 × 50.9 mm 79.0 × 50.9 mm Maximum engine speed 14750 rpm 14500 rpm 14500 rpm (limiter controlled speed) Compression ratio 13.0 – 13.4 13.0 13.0 Depending on (recommended value) head surface grinding...

  • Page 5: Kit Parts

    Kit Parts 2-1 Installing Electrical Parts ECU Set (B3L-8591A-70) Parts List PART No. PART NAME Q'TY REMARKS B3L-8591A-70 B3L-2818Y-70 YMS SOFT & MANUAL '20 Ver. R1 EN2911 2019Rev <Setting-up Details> • Use of this set and a wire har ness STK specification: included in the kit enables regulation (or setting) of fuel injection and ignition timing, Base Data for STK (R1-20_BaseData_00_STK.ycz)
  • Page 6 The set of the camshaft, valve spring, ECU and air funnel must be used in the following combination. VALVE SPRING WIRE HARNESS METER(REPAIR MODEL SHAFT CAM 1 INT SHAFT CAM 2 EXT AIR FUNNEL SET ECU SET SET) 2015 MGC-191114-00 2CR-8591A-70 R1:2CR-83500-00 2CR-A2110-70...

  • Page 7: Cable Interface (2Cr-8533A-70)

    (commercially available) to the vehicle using the genuine Yamaha part "90890-03249 OBD/ GST LEADWIRE KIT". For details,refer to the STD service manual published by Yamaha Motor Co.,Ltd. You can purchase "90890-03249 OBD/GST LEADWIRE KIT" at any Yamaha part dealer. R1EN12102019Rev – 4 –...
  • Page 8 DTC　English name/check item DTC　English name/check item DTC CODE DTC CODE P0475 Exhaust Pressure Control Valve "A" C0520 Multi-axis Acceleration Sensor Module "A" C1000 Steering Damper Solenoid Control Circuit P0476 Exhaust Pressure Control Valve "A" Range/Performance P0030 HO2S Heater Control Circuit Bank 1 Sensor 1 P0480 Fan 1 Control Circuit P0050...

  • Page 9: Wire Harness Set (B3L-F2590-70)

    Wire Harness Set (B3L-F2590-70) Parts List PART No. PART NAME Q'TY REMARKS B3L-82590-70 WIRE HARNESS ASSY. ○ B3L-82386-70 WIRE,SUB-LEAD for TH INJECTOR ○ B3L-82318-70 WIRE,SUB-LEAD for AC INJECTOR ○ B3L-82309-70 WIRE,SUB-LEAD for IG. COIL ○ 2CR-8231Y-70 WIRE,LEAD for FUEL PUMP ○ B3L-83553-70 WIRE,LEAD for METER For REC./REG.

  • Page 10: Wire, Sub-Lead(2Ks-82509-70)

    4. WIRE, SUB-LEAD(2KS-82509-70) Parts List PART No. PART NAME Q'TY REMARKS 2KS-82509-70 WIRE, SUB-LEAD This wire harness is for mounting the KIT harness to a vehicle with the Electric racing suspension (ERS) function. If the E-SD (STD steering damper) is not used, removing its coupler will pose no problem.
  • Page 11 Installing Wire Harness: 1. Remove the STD wire harness from the chassis. 2. Remove the side cover bracket(left) from the vehicle. 3. Install the PLUG to the BRKT.,UNDER ⑫ ⑬ 4. Install the BRKT.,UNDER using the BOLT,HEX.SOCKER BUTTON the frame. ⑫ ⑫ ⑮...
  • Page 12 6. Remove the Hydraulic unit and EXUP servo motor from the vehicle. I n s t a l l t h e H y d r a u l i c u n i t u s i n g t h e B O L T , B U T T O N H E A D t o t h e BRKT.,CONTROL UNIT...
  • Page 13 8. Remove from the chassis the STD rectifier/regulator that is installed on the right side of the radiator. 9. I n s t a l l t h e B R K T. , R E G U L AT O R 1 using the BOLT.,BUTTON HEAD WASHER,PLAIN to the vehicle.
  • Page 14 11. Install the wire harness of the kit as the diagram. – 11 – R1 EN2911 2019Rev...
  • Page 15 METER MAIN SW AC INJECTOR 2 AC INJECTOR 3 AC INJECTOR 1 AC INJECTOR 4 ⑥B3L-82318-70 内は接続する部品の名称です。 indicate the names of parts to be 　WIRE,SUB-LEAD connected. 　 for AC INJECTOR R1 EN2911 2019Rev – 12 –...
  • Page 16 R1 EN2911 2019Rev – 13 –...
  • Page 17 The name and function of each switch <Left> Keep the switch at low position Hi position→the LAP switch becomes non-functional Mode switch Up button LAP switch Center button Down button Not used Pit road limiter MAP SELECT →MAP 1 PUSH=OFF →MAP 2 <Right>...
  • Page 18 YRC : Yamaha Ride Control PWR : Power Delivery Mode Yamaha Ride Control is a system that controls the engine output based on data The power mode selection system consists of received from the sensors and IMU. four different control maps to regulate throttle T h e f u n c t i o n s l i s te d b e l o w r e p r e s e nt...
  • Page 19 SCS : Slide control system LIF : Lift control system The slide control system controls engine The lift control system reducing wheel lift rate power output when a sideward slide is during extreme acceleration, such as during detected in the rear wheel. starts or out-of-corner acceleration. It adjusts output to an optimum level based When front-wheel lift is detected by the IMU, on data from the IMU, thus helping the rider engine output is adjusted to the optimum...
  • Page 20 About the front and rear wheel speed sensor Do not remove the speed sensors installed at the front and rear wheels because they are used for regulating YRC controls. • If you change the front and rear wheels to non-standard parts, manufacture and attach a rotor and sensor referring to the diagram below.

  • Page 21: Headlight Harness Set (Bx4-F4350-71)

    Headlight Harness Set (BX4-F4350-70) Parts List Headlight Harness Set (BX4-F4350-71) Parts List PART No. PART NAME Q'TY REMARKS BX4-84359-71 CORD, HEAD LIGHT Light ON/OFF SW. x 2 5GF-83976-00 SW., HANDLE 1 Emergency SW. This set is used in endurance races in combination with the kit harness for turning on the STD headlights and taillights.

  • Page 22: Repair Set

    Repair set Select the part set corresponding to your model. Parts List 2CR-28130-70 (for 2015~2017 YZF-R1(2CR/BX4)) PART No. PART NAME Q'TY REMARKS 2CR-83500-00 METER ASSY. 2CR-83963-00 SWITCH HANDLE 3 2CR-83969-00 SWITCH HANDLE 5 2CR-85970-00 FR.WHEEL SENSOR 2CR-85980-00 RR.WHEEL SENSOR R1J20191108Rev Parts List BX4-28130-80 (for 2018,2019 YZF-R1(BX4)) PART No.
  • Page 23 Parts List 2KS-28130-70 (for 2015~2017 YZF-R1M (2KS)) PART No. PART NAME Q'TY REMARKS 2KS-83500-00 METER ASSY. 2CR-83963-00 SWITCH HANDLE 3 2CR-83969-00 SWITCH HANDLE 5 2CR-85970-00 FR.WHEEL SENSOR 2CR-85980-00 RR.WHEEL SENSOR R1YEC20191005Rev Parts List 2KS-28130-80 (for 2018, 2019 YZF-R1M(2KS/BAF)) PART No. PART NAME Q'TY REMARKS 2KS-83500-60 METER ASSY.

  • Page 24: Ccu Comp. (2Ks-85800-72)

    CCU COMP. (2KS-85800-72) The CCU of R ACING KIT PARTS is The CCU (Communication control unit) equipped with the general-purpose analog facilitates checking or settings of the vehicle voltage (0 to 5 V) interface. information, and enhances rider's relationship with the vehicle. For information about the standard features, The CCU COMP.
  • Page 25 Preparation • Install the units to the vehicle. When using it for the first time, check if the GPS icon lights up on the meter before riding. The gray and black cable is for AIN-1 (It may take about 10 minutes for GPS positioning even in an outdoor location.) (analog Ch1), and the purple and black cable is for AIN-2 (analog Ch2).
  • Page 26 CCU (when communicating with the CCU) or Internet (when displaying the map) according to the use. Connecting to the CCU Label on the CCU (See Fig.3.) ddeeff Network name (SSID) YAMAHA MOTOR CCU MAC: aa-bb-cc-dd-ee-ff Password 12345678 S/N: 12345678 (Fig.
  • Page 27 <Example 1> When the following is stated in the When viewing logging data, analog Ch is sensor's manual not displayed by Y-TRAC default setting. "AF value: voltage x 1.6 +10" To display it, tap Graph Setting in the Graph Option mode. Factor 1.6000 Offset 10.0000 Min Y-axis 10.00 Max Y-axis 20.00...
  • Page 28 Other usages Meter setting To indicate CCU's detection of line passing on the meter, enable the stop watch function on the meter (blink ":" (column) and "." (period) in area 2). 12 : 00 A - 2 1000 r/min × 03 06 GEAR LATEST...

  • Page 29: Installing Engine Parts

    2-2 Installing Engine Parts Maintenance Set (2CR-MAINT-72) Parts List PART No. PART NAME Q'TY REMARKS 2CR-11181-00 GASKET, CYLINDER HEAD 1 t=0.60 mm (STD) 2CR-11351-00 GASKET, CYLINDER 1 t=0.20 mm (STD) 2CR-11603-10 PISTON RING SET 2CR-1165A-00 BOLT, CONNECTING ROD SPECIAL 93450-18169 CIRCLIP 3P6-12129-00 SEAL, VALVE STEM OIL 2 4TE-12119-00 SEAL, VALVE STEM OIL BX4-13414-00...

  • Page 30: Spark Plug Set (14B-R465B-70)

    Spark Plug Set (14B-R465B-70) Parts List PART No. PART NAME Q'TY REMARKS 14B-1119C-70 PLUG, SPARK NGK R0465B-10 The spark creating portion of this spark plug is of a semi-surface discharge type of shape. Since these spark plugs have a copper gasket, caution needed during installation on the following points.

  • Page 31: Piston Set (2Cr-116A0-71)

    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) 12. Crankshaft (B3L-11400-70) Parts List PART No. PART NAME...
  • Page 32 2016 to2020 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. R1 EN2911 2019Rev – 29 –...

  • Page 33: High-Lift Camshafts

    13. High-lift Camshafts Parts List PART No. PART NAME Q'TY REMARKS B3L-12170-70 CAM SHAFT ASSY. B3L-12180-70 CAM SHAFT ASSY. 締付トルク24±2Nm 14. Cam Sprocket(B3L-12176-70) PART No. PART NAME Q'TY REMARKS B3L-0012176-70 SPROCKET, CAM INT/EXT-shared use Possible to adjust the valve timing using the long holes on the cam sprocket.
  • Page 34 NOTICE Using in other combinations may possibly damage the engine. Be sure to use in the combination as stated below. VALVE SPRING WIRE HARNESS METER(REPAIR MODEL SHAFT CAM 1 INT SHAFT CAM 2 EXT AIR FUNNEL SET ECU SET SET) 2015 MGC-191114-00 2CR-8591A-70...
  • Page 35 Installation 1. Fit the scratch line on the camshaft to the compression top dead point 105 degree (K Install the cam sprocket as the scratch mark position) to combine the camshaft line and BX4 mark face the outside of the and cylinder head surface.

  • Page 36: Air Funnel Set (B3L-1440B-70)

    15. Air Funnel Set (B3L-1440B-70) Parts List PART No. PART NAME Q'TY REMARKS B3L-14479-70 SECONDARY FUNNEL B3L-14469-70 PRIMARY FUNNEL 1 92014-06025 BUTTON HEAD BOLT B3L-1446C-70 PRIMARY FUNNEL 2 92014-06025 BUTTON HEAD BOLT R1 EN2911 2019Rev Installation 1. Assembling the primary funnel The STD seal rubber is not used at the Secure the primary funnel 1 and 2 to the bottom sur face (face to the primar y throttle body with the supplied button head...
  • Page 37 The set of the camshaft, valve spring, ECU and air funnel must be used in the following combination. NOTICE Using in other combinations may possibly damage the engine. Be sure to use in the combination as stated below. VALVE SPRING WIRE HARNESS METER(REPAIR MODEL...

  • Page 38: Ais-Plug Set (2Cr-A4890-70)

    16. AIS-plug Set (2CR-A4890-70) This plug set is used when the AIS (Air Induction System), an exhaust gas purifying system, is removed. Parts List PART No. PART NAME Q'TY REMARKS 5SL-1482L-70 PLATE, 2 2CR-11159-70 PLUG, BLIND 90336-10020 PLUG, TAPER Installation 1. Remove the hose attached to the cylinder 4.

  • Page 39: Transmission Gear

    17. Transmission Gear Parts List PART No. PART NAME Q'TY REMARKS 2CR-17401-70 MAIN AXLE ASSY. 2CR-17121-70 GEAR, 2ND PINION 2CR-17131-70 GEAR, 3RD PINION 2CR-17151-70 GEAR, 5TH PINION A 2CR-17151-80 GEAR, 5TH PINION B 2CR-17161-70 GEAR, 6TH PINION A 2CR-17161-80 GEAR, 6TH PINION B 2CR-17402-00 DRIVE AXLE ASSY.
  • Page 40 15 / NOTICE This set contains modified gear ratios and docks compared with the STD gearbox. Kit gears cannot use combine standard gear. Gear ratio 39/15 (2.600) 39/16 (2.438) 37/17 (2.176) 35/17 (2.059) 35/19 (1.842) 34/19 (1.789) 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)
  • Page 41 – 38 –...

  • Page 42: Mission Maintenance Set (2Cr-A7000-70)

    18. Mission Maintenance Set (2CR-A7000-70) Parts List PART No. PART NAME Q'TY REMARKS 90387-28003 COLLAR 90209-25011 WASHER 93440-28184 CIRCLIP 90387-25023 COLLAR 90214-25004 WASHER, CLAW 90214-25003 WASHER, CLAW 90387-31003 COLLAR 90209-28008 WASHER 93440-31187 CIRCLIP 90387-28004 COLLAR 90214-29002 WASHER, CLAW 90214-28002 WASHER, CLAW 90387-25008 COLLAR 93102-40330 SEAL, OIL 93440-62032...
  • Page 43 30 32 – 40 –...
  • Page 44 Transmission Assembly The seal side should face outward (one side seal bearing) and press in the bearing cup all the way into the case until it touches bottom. Apply molybdenum oil to inside of diameter. After assembly, it should rotate smoothly. Apply molybdenum oil to the inside diameter and end.

  • Page 45: Drive Sprockets

    19. Drive Sprockets Parts List PART No. PART NAME Q'TY REMARKS 2CR-17460-74 SPROCKET, DRIVE 14T, 520SIZE 2CR-17460-75 SPROCKET, DRIVE 15T, 520SIZE 2CR-17460-76 SPROCKET, DRIVE 16T, 520SIZE This sprocket is weight-saved by changing the chain size to 520 in relation to the STD one. –...

  • Page 46: Sprocket Nut Set (2Cr-A7463-70)

    20. Sprocket Nut Set (2CR-A7463-70) Parts List PART No. PART NAME Q'TY REMARKS 90179-22018 90208-22002 WASHER, CONICAL SPRG. Apply swage after tightening a nut The “OUT” mark must face outward – 43 –...

  • Page 47: Strainer Cover Set (2Cr-13400-71)

    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. Meaning of the symbol marks in the figures : Apply LOCTITE 620...
  • Page 48 Installation 1. Put (8) O-RING at (7) PIPE,OIL 1, and connect (6) PIPE,OIL 2 to (7 )PIPE,OIL 1. 2. Attach (6) PIPE,OIL 2 to the engine by using (8) O-RING and (9) BOLT,HEX. SOCKET. 3. Attach (7)PIPE,OIL 1 and (23)BRKT.,STRAINER 1 to the engine by using(8)O-RING and(10) BOLT,HEX.
  • Page 49 6. Fix (1) STRAINER HSG.ASSY., 11 PIPE, DELIVERY 1 and (23)BRKT.,STRAINER 1 b y u s i n g ( 1 2 ) G R O M M E T, ( 1 3 ) COLLAR,DISTANCE, (14) BOLT and (22) WASHER,PLAIN. 7.
  • Page 50 8. Attach (15) PAN,OIL to the engine by using (16)BOLT,BUTTON HEAD. B e s u r e t o c h e c k t h e t o r q u e w h e n installing. 9. Attach (17)PLUG,STRAIGHT SCREW and (18 )GASKET to (15)PAN,OIL.
  • Page 51 Recommended oil level After engine warm-up (water temperature of 75 to 80 degrees), while using the racing (rear) stand, 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).

  • Page 52: Installing Chassis Parts

    2-3 Installing Chassis Parts 22. Spring Rear Shock Parts List PART No. PART NAME Q'TY REMARKS 2CR-22222-A0 SPRG., REAR SHOCK 83 N/mm Identifying stamp: 159.5-56-83 2CR-22222-70 SPRG., REAR SHOCK 93 N/mm Identifying stamp: 159.5-56-93 2CR-22222-75 SPRG., REAR SHOCK 98 N/mm Identifying stamp: 159.5-56-98 2CR-22222-80 SPRG., REAR SHOCK 103 N/mm Identifying stamp: 159.5-56-103...

  • Page 53: Spring Front Fork

    23. Spring Front Fork Parts List PART No. PART NAME Q'TY REMARKS 9.5 N/mm BN6-2314-75 SPRG., FRONT FORK Identifying slits 1 10.0 N/mm BN6-23141-80 SPRG., FRONT FORK Identifying slits 2 • There are slits at the ends of the spring for rate identification. 9.5 N/mm 10.0 N/mm •...
  • Page 54 References Front and rear load changes and front and rear suspension movement in different scenarios. Accelerating . Load change The wider the throttle is opened, the more the load is concentrated on the rear. . Front fork Reaches nearly maximum extended stroke. .

  • Page 55: Seat Cushion (13S-24713-70)

    24. Seat Cushion (13S-24713-70) Parts List PART No. PART NAME Q'TY REMARKS 13S-24713-70 CUSHION SEAT Anti slip seat. Cut to any size for use. – 52 –...

  • Page 56: Front Spare Wheel Ass'y (2Cr-25100-70)

    25. Front Spare Wheel ASS’Y (2CR-25100-70) Parts List PART No. PART NAME Q'TY REMARKS 2CR-25160-00 CAST WHEEL ASSY. 93900-00030 VALVE, RIM 1SD-2517G-00 ROTOR, SENSOR 2CR-2514A-00 RING, WHEEL 1 90149-05037 SCREW 93210-47440 O-RING *This kit does not include a tire. This part is the STD wheel, bearing, spacer, air valve and center rotor combined.

  • Page 57: Rear Spare Wheel Ass'y (B3L-25300-70)

    26. Rear Spare Wheel ASS’Y (B3L-25300-70) Parts List PART No. PART NAME Q'TY REMARKS B3L-25370-00 CAST WHEEL ASSY. B3L-25840-00 DISK BRAKE ASSY. 90111-08085 BOLT, HEX. SOCKET BUTTON 93900-00030 VALVE, RIM R1 EN2911 2019Rev *This kit does not include a tire. This part is the STD wheel, bearing, spacer, air valve, rear disk brake and center rotor combined.

  • Page 58: Rear Sprocket

    27. Rear Sprocket Parts List PART No. PART NAME Q'TY REMARKS B3L-12170-70 Rr. SPROCKET 38T B3L-12180-70 Rr. SPROCKET 39T B3L-12180-71 Rr. SPROCKET 40T B3L-12180-72 Rr. SPROCKET 41T B3L-12180-73 Rr. SPROCKET 42T B3L-12180-74 Rr. SPROCKET 43T B3L-12180-75 Rr. SPROCKET 44T B3L-12180-76 Rr. SPROCKET 45T B3L-12180-77 Rr.

  • Page 59: Tube Guide (B3L-26243-70)

    28. Tube Guide (B3L-26243-70) Parts List PART No. PART NAME Q'TY REMARKS B3L-26243-70 TUBE, GUIDE About the Throttle Tube Guide Specifications As shown below, the operating angle 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) ’20 KIT specification Throttle body opening...

  • Page 60: Tightening Torque List

    Tightening Torque List Engine To be tightened Part No. Part Name Thread dia. Tightening Q’ty Remarks torque N•m pitch (kgf•m) Plug for sand 90340-18004 PLUG, M18 × 1.5 25 ± 2 APPLY LOCKING STRAIGHT (2.5 ± 0.2) AGENT drain hole SCREW (LOCKTITE® TO BOTH SCREW THREAD AND...
  • Page 61 Engine To be tightened Part No. Part Name Thread dia. Tightening Q’ty Remarks torque N•m pitch (kgf•m) 90110-06168 BOLT, M6 x 1.0 10±2 APPLY TO SCREW HEAD x JOINT, HEXAGON (1.0±0.2) ROCKING ASSY SOCKET HEAD ROCKER AXIS 90340-12013 PLUG, M12 x 1.0 10±2 APPLY TO SCREW STRAIGHT (1.0±0.2)
  • Page 62 Engine To be tightened Part No. Part Name Thread dia. Tightening Q’ty Remarks torque N•m pitch (kgf•m) 90110-06163 BOLT, M6 x 1.0 10±2 The rear of the Install THERMO- HEXAGON (1.0±0.2) head cylinder STAT ASSY. SOCKET HEAD Install PIPE 1 90105-06127 BOLT, M6 x 1.0...
  • Page 63 Engine To be tightened Part No. Part Name Thread dia. Tightening Q’ty Remarks torque N•m pitch (kgf•m) 5GH-13440-60 OIL M20 x 1.5 17±2 APPLY Install OIL CLEANER (1.7±0.2) GREASE CLEANER ASSY TO O-RING. ASSY Install OIL PAN 90111-06168 BOLT, M6 x 1.0 10±2 APPLY TO SCREW HEXAGON...
  • Page 64 Engine To be tightened Part No. Part Name Thread dia. Tightening Q’ty Remarks torque N•m pitch (kgf•m) 98907-05020 SCREW, M5 x 0.8 2.0±0.5 10 (TARGET UPPER BINDING (0.2±0.05) VALUE OF COVER HEAD 2.0 N•m) AIR FILTER 90110-06233 BOLT. M6x1.0 6.5-8.0 HEXAGON (0.65-0.8) CASE...
  • Page 65 Engine To be tightened Part No. Part Name Thread dia. Tightening Q’ty Remarks torque N•m pitch (kgf•m) 95812-08060 BOLT, M8 x 1.25 24±2 APPLY OIL TO CRANKCASE 1 FLANGE (2.4±0.2) BOTH SCREW x CRANKCASE 2 THREAD AND BEARING. CRANKCASE 1 90109-06100 BOLT M6 x 1.0...
  • Page 66 Engine To be tightened Part No. Part Name Thread dia. Tightening Q’ty Remarks torque N•m pitch (kgf•m) 90149-06158 SCREW M6 x 1.0 10±2 APPLY TO SCREW Install PLATE, (1.0±0.2) ROCKING BREATHER Install PLUG to 90340-27003 PLUG, M27 x 1.5 15±2 FOR CRANK STRAIGHT (1.5±0.2)
  • Page 67 Engine To be tightened Part No. Part Name Thread dia. Tightening Q’ty Remarks torque N•m pitch (kgf•m) 90179-20007 M20 x 1.0 125±5 APPLY OIL TO Install CLUTCH (12.5±0.5) BOTH SCREW BOSS THREAD AND BEARING. 1 POINT SWAG- ING AFTER TIGHTENING Install CLUTCH 2CR-16337-00 SCREW, M6 x 1.0...
  • Page 68 Engine To be tightened Part No. Part Name Thread dia. Tightening Q’ty Remarks torque N•m pitch (kgf•m) 90110-05034 BOLT, M5 x 0.8 6±1 APPLY TO SCREW Install PICKUP HEXAGON (0.6±0.1) ROCKING ASSY SOCKET HEAD OIL PRESSURE 1WS-82504-00 SW. OIL PT1/8 12.5±2 When mended, use PRESSURE...
  • Page 69 Chassis To be tightened Part No. Part Name Thread dia. Tightening Q’ty Remarks torque N•m pitch (kgf•m) 90110-12007 BOLT, M12 x 1.25 64 – 76 PROCEDURE E/G BRACKET, HEXAGON (6.4 – 7.6) TO INSTALL FRONT, LEFT SOCKET THE ENGINE. FOR DETAILS, SEE page 74.
  • Page 70 Chassis To be tightened Part No. Part Name Thread dia. Tightening Q’ty Remarks torque N•m pitch (kgf•m) 90185-20008 NUT, SELF M20 x 1.5 80 – 130 PROCEDURE SHAFT, PIVOT LOCKING (8.0 – 13.0) TO INSTALL THE & U NUT PIVOT SHAFT PERIPHERAL PARTS.
  • Page 71 Chassis To be tightened Part No. Part Name Thread dia. Tightening Q’ty Remarks torque N•m pitch (kgf•m) 91380-06025 BOLT, M6 x 1.0 5 – 8 HANDLE and HEXAGON (0.5 – 0.8) HANDLE, SOCKET CROWN HEAD STEERING 90179-30691 M30 x 1.0 40 –...
  • Page 72 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 73: Tightening The Cylinder Head

    Tightening the Cylinder Head 1. In the following order (1→10), apply initial tightening of 10 N•m (1.0 kgf•m). 2. In the following order (1→10), apply additional tightening of 25 N•m (2.5 kgf•m). 3. In the following order (1→10), apply additional tightening of 45 N•m (4.5 kgf•m). 4. In the following order (1→10), loosen each bolt.

  • Page 74: Installing The Crankcase

    Installing the Crankcase 1. T i ghten t he b o lt s in t he t i ghtening sequence of 1 to 10 to 20 N•m (2.0 kg•m). The numbers 1 to 40 show the sequence 2. After loosening the bolts once in the in which the bolts are tightened.

  • Page 75: Procedure To Tighten The Aluminum Bolts

    Procedure to tighten the aluminum bolts 1. In the following order, tighten the bolt at 6N•m (0.6kgf•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°.

  • Page 76: When Replacing Aluminum Bolts With Iron Bolts

    When replacing aluminum bolts with iron bolts Use the following table as a reference when replacing aluminum bolts with iron bolts. To be tightened Part No. Part Name Thread dia. Tightening Q’ty Remarks torque N•m pitch (kgf•m) Install COVER, 90110-06390 BOLT, M6 x 1.0 12±2...

  • Page 77: Procedure To Install The Engine

    Procedure to install the engine (unchangeable) 1. Attach the two engine adjusting bolts 1 to the frame COMP. temporarily. For information about tightening torque 2. Fit the engine installation position to the and requirement for lubricant agent, see frame COMP and attach the bolts 2 and 3 the list of tightening torque.

  • Page 78: Procedure To Install The Pivot Shaft Peripheral Parts

    Procedure to install the pivot shaft peripheral parts 1. Tighten the pivot shaft 1 at specified torque. For information about tightening torque 2. Tighten the nut 2 at specified torque. and requirement for lubricant agent, see 3. Tighten the nut 3 (self-rocking) at the list of tightening torque. specified torque.

  • Page 79: Headlight Cord Wiring Diagram

    – 76 –...

  • Page 80: Yzf-R1 Wiring Diagram

    YZF-R1 Wiring Diagram – 77 –...
  • Page 81 REC/REG PC_I/F CAM_SNSR CCU1 CCU2 GPS1 GPS2 LIGHT_SW. A-MAP_SELECT_SW. L/W B/W R/G B/W L/B L/W Br/W B/W L/B L/W R/G L/B BLACK BLACK BLACK BLACK BLACK BLACK DARK_GRAY BLACK INJ_42 INJ_22 INJ_32 INJ_12 SHIFT_SNSR IG_COIL_2 IG_COIL_4 IG_COIL_3 IG_COIL_1 THROTTLE_MOTOR WT_SNSR PB_SNSR Gy/R Gy/G...
  • Page 82 Published by YAMAHA MOTOR ENGINEERING co., LTD...

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