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Yamaha YZF-R1 2022 Manual
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Yamaha YZF-R1 2022 Manual

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Summary of Contents for Yamaha YZF-R1 2022

  • 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 CONTENTS ................. 1 2 Kit Parts ......................2 2-1 Installing Electrical Parts ................2 ECU Set (B3L-8591A-72/B3L-8591A-A0) ............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 ......................19 CCU COMP.
  • Page 4 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 14750 rpm 14500 rpm (limiter controlled speed) Compression ratio 13.0 – 13.4 13.0 13.0 (recommended value) Valve timing (event angle) 105°...
  • Page 5 1. ECU Set (B3L-8591A-72/B3L-8591A-A0) Parts List for SBK PART No. PART NAME Q'TY REMARKS B3L-8591A-72 ECU SET for SBK B3L-2818Y-73 YMS SOFT & MANUAL for SST PART No. PART NAME Q'TY REMARKS B3L-8591A-A0 ECU SET for SST B3L-2818Y-73 YMS SOFT & MANUAL ECU of this set.
  • Page 6 The set of the camshaft, cam sprocket, valve spring, ECU and air funnel must be used in the following combination. SHAFT CAM 1 SHAFT CAM 2 VALVE SPRING AIR FUNNEL WIRE HARNESS METER(REPAIR MODEL ECU SET SPROCKET SET) 2015 MGC-191114-00 2CR-8591A-70 2016 R1:2CR-83500-00 2CR-A2110-70...
  • Page 7 (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 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 HO2S Heater Control Circuit Bank 2 Sensor 1 Exhaust Pressure Control Valve "A"...
  • Page 9 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. B3L-2128A-70 BRKT., REGULATOR 1 92017-06020 BOLT,BUTTON HEAD 90201-07081...
  • Page 10 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. 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 4. Install the BRKT.,UNDER using the BOLT,HEX.SOCKER BUTTON the frame. 5. Install the ECU and BRKT.,UPPER using theBOLT,FLG to the BRKT.,UNDER...
  • Page 12 6. Remove the Hydraulic unit and EXUP servo motor from the vehicle. I n s t a l l t h e Hyd 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 EG U L ATO 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 indicate the names of parts to be connected. R1 EN2911 2019Rev – 12 –...
  • Page 16 R1 EN2911 2019Rev – 13 –...
  • Page 17 The name and function of each switch <Left> <Right> R1 EN0102 2022Rev – 14 –...
  • Page 18 YRC : Yamaha Ride Control Yamaha Ride Control is a system that PWR : Power Delivery Mode controls the engine output based on data The power mode selection system consists of received from the sensors and IMU. T h e f u nc t io n s li s t e d b e low re p re s ent...
  • 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.
  • 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 Parts List 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 Select the part set corresponding to your model. Parts List 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 PART No. PART NAME Q'TY REMARKS BX4-83500-30...
  • Page 23 Parts List 2KS-28130-70 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 PART No. PART NAME Q'TY REMARKS 2KS-83500-60 METER ASSY. 2CR-83963-00 SWITCH HANDLE 3 2CR-83969-00 SWITCH HANDLE 5 2CR-85970-00...
  • Page 24 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 CCU unit will be used as the password for wireless LAN connection between the tablet and CCU, be sure to write down the...
  • Page 26 (Fig. 1.) (Fig. 2.) When connecting the tablet to the network, select CCU (when communicating with Connecting to the CCU Label on the CCU (See Fig.3.) Network name (SSID) YAMAHA MOTOR CCU MAC: aa-bb-cc-dd-ee- Password 12345678 S/N: 12345678 (Fig. 3.)
  • 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 10.0000...
  • 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). <Wheel switch operation procedure> Press the wheel switch to blink area 1. Rotate the wheel switch to blink area 2.
  • Page 29 Parts List PART No. PART NAME Q'TY REMARKS B3L-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 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 Parts List PART No. PART NAME REMARKS Q'TY B3L-11181-70 GASKET CYLINDER HEAD t=0.45mm Stamp:00 B3L-11181-80 GASKET CYLINDER HEAD t=0.50mm Stamp:01 B3L-11181-90 GASKET CYLINDER HEAD t=0.55mm Stamp:02 *the thickness of a standard part is t=0.60mm. This parts are used to adjust the compression ratio for improving performance by selecting given gasket (thickness).
  • Page 32 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) Parts List PART No. PART NAME Q'TY...
  • Page 33 2016 to 2022 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 EN0102 2022Rev – 30 –...
  • Page 34 Parts List PART No. PART NAME Q'TY REMARKS B3L-12170-80 SHAFT CAM 1 B3L-12180-80 SHAFT CAM 2 Tightening torque 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. R1 EN0102 2022Rev –...
  • 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 The set of the camshaft, cam sprocket, valve spring, ECU and air funnel must be used in the following combination. SHAFT CAM 1 SHAFT CAM 2 VALVE SPRING AIR FUNNEL WIRE HARNESS METER(REPAIR MODEL ECU SET SPROCKET SET) 2015 MGC-191114-00 2CR-8591A-70 2016 R1:2CR-83500-00 2CR-A2110-70...
  • Page 37 Parts List PART No. PART NAME Q'TY REMARKS 0WX2-12176-00 CAM SPROCKET INT/EXT-shared use 0WX2-90003-00 HOLDER, CAM SPROCKET 0WX2-90004-00 SCREW, CAM SPROCKET This part is attached to the STD camshaft and changes the valve timing to improve the output. Installation 1. Mark the camshaft end face on the sprocket mountain centerline at the "I" mark on the INT/EXT cam sprocket.
  • Page 38 4.Assemble the kit cam sprocket in the position where the mark made in step 1. and the "B3L" mark are diagonal. 12 ± 2 N m 12 ± 2 N m "B3L" mark 5.When assembling to the cylinder head, align the center of the two exhaust marks on the kit cam sprocket with the top surface of the exhaust side cylinder head.
  • Page 39 The set of the camshaft, cam sprocket, valve spring, ECU and air funnel must be used in the following combination. SHAFT CAM 1 SHAFT CAM 2 VALVE SPRING AIR FUNNEL WIRE HARNESS METER(REPAIR MODEL ECU SET SPROCKET SET) 2015 MGC-191114-00 2CR-8591A-70 2016 R1:2CR-83500-00 2CR-A2110-70...
  • Page 40 Parts List PART No. PART NAME Q'TY REMARKS 2CR-12130-71 SRG'ASSY.1 I.D.Color: Blue (INT) 2CR-12140-71 SRG'ASSY.2 I.D.Color: Red (EXT) 2CR-12117-00 RET.VALVE SPRING 2CR-12127-00 RET.VALVE SPRING2 This valve spring is used when the camshaft is mounted from the kit. This set consists of a valve spring, a valve spring seat and a retainer valve spring. The set of the camshaft, cam sprocket, valve spring, ECU and air funnel must be used in the following combination.
  • Page 41 Parts List PART No. PART NAME Q'TY REMARKS B3L-14479-80 SECONDARY FUNNEL B3L-14469-80 PRIMARY FUNNEL 1 92014-06025 BUTTON HEAD BOLT B3L-1446C-80 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 42 The set of the camshaft, cam sprocket, valve spring, ECU and air funnel must be used in the following combination. SHAFT CAM 1 SHAFT CAM 2 VALVE SPRING AIR FUNNEL WIRE HARNESS METER(REPAIR MODEL ECU SET SPROCKET SET) 2015 MGC-191114-00 2CR-8591A-70 2016 R1:2CR-83500-00 2CR-A2110-70...
  • Page 43 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 44 Parts List PART No. PART NAME REMARKS Q'TY 90387-06037 COLLAR This spacer is intended to reduce rear tire hopping during deceleration. Installation 1. Install between the pressure plate 1 and the pressure plate 2. 2. Remove the clutch cover damper plate and clutch cover damper from the clutch cover, then install the clutch cover.
  • Page 45 PART No. PART NAME Q'TY REMARKS B3L-16371-70 BOSS,CLUTCH B3L-16350-70 PRESSURE PLATE ASSY.,1 By using this part together with Clutch Spring Spacer(B3L-16332-70),the hopping of the rear tire during deceleration can be further reduced. R1 EN0102 2022Rev – 42 –...
  • Page 46 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 47 NOTICE 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) 30/24 (1.250) 30/22 (1.364)
  • Page 48 – 45 –...
  • Page 49 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 CIRCLIP 90201-257H0...
  • Page 50 – 47 –...
  • Page 51 Transmission Assembly – 48 –...
  • Page 52 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 53 Parts List PART No. PART NAME Q'TY REMARKS 90179-22018 90208-22002 WASHER, CONICAL SPRG. – 50 –...
  • Page 54 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. – 51 –...
  • Page 55 Installation 1. Put ( O-RING at ( PIPE,OIL 1, and connect (6) PIPE,OIL 2 to (7 )PIPE,OIL 1. 2. Attach PIPE,OIL 2 to the engine by using (8) O-RING and ( BOLT,HEX. SOCKET. 3. Attach PIPE,OIL 1 and ( BRKT.,STRAINER 1 to the engine by using(8)O-RING and(10) BOLT,HEX.
  • Page 56 6. Fix STRAINER HSG.ASSY., 11 PIPE, DELIVERY 1 and (23)BRKT.,STRAINER 1 b y u s i n g ( G R O M M E T, ( COLLAR,DISTANCE, ( BOLT and ( WASHER,PLAIN. 7. A t t ac h (2 0) B A FFLE , PL AT E t o ( PAN,OIL by using 21 BOLT.
  • Page 57 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 58 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 59 Parts List PART No. PART NAME Q'TY REMARKS B3L-13411-70 STRAINER,OIL 1 attachment 2HC-13411-00 STRAINER,OIL 1 attachment 93210-22M93 O-RING 1, 10 attachment 91312-06020 BOLT,HEX. SOCKET HEAD 1 attachment 0WX2-90013-00 PLATE,STOPPER 5 attachment 91312-06016 BOLT,HEX. SOCKET HEAD 90480-13010 1, 25, 34 attachment GROMMET 1, 25, 34 attachment 5VY-13117-10...
  • Page 60 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. Installation 1. Assemble 14, 15, 16 and 17 to 13.
  • Page 61 3. Pass 22 through 21 and assemble to 20. 4. Pass 22 through 20 and secure it to the engine with 23. 5. Fasten 21 and 34 to the engine with 24. 6. Fix 10 and 11 to the engine with 12. 7.
  • Page 62 9. Assemble 1, 25, and 34 using 7, 8, 9, and 33. 10. Assemble the 19 to the 10 and 13. R1 EN0102 2022Rev – 59 –...
  • Page 63 7. Attach 31 BAFFLE,PLATE to 26 PAN,OIL by using 32 BOLT. 8. Put 30 between 26 and the engine, and assemble 26 to the engine with 27. 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.
  • Page 64 Recommended oil level Af ter the engine has warmed up (water temperature 75-80°C), stop the engine and limit of the oil pan window on the right side of the vehicle with the racing (rear) stand in place. Add another 200cc from there. <Oil pan window (right side of vehicle)>...
  • Page 65 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 2CR-22222-85...
  • Page 66 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 9.5 N/mm 10.0 N/mm •...
  • Page 67 References – 64 –...
  • Page 68 Parts List PART No. PART NAME Q'TY REMARKS 13S-24713-70 CUSHION SEAT Anti slip seat. Cut to any size for use. – 65 –...
  • Page 69 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 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 71 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 72 Parts List PART No. PART NAME Q'TY REMARKS B3L-26243-70 TUBE, GUIDE 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) KIT specification Throttle body opening...
  • Page 73 Engine To be tightened Part No. Part Name Thread dia. Tightening Q’ty Remarks torque N•m pitch (kgf•m) 90340-18004 PLUG, Plug for sand M18 × 1.5 25 ± 2 APPLY LOCKING STRAIGHT (2.5 ± 0.2) AGENT drain hole SCREW (LOCKTITE® TO BOTH SCREW THREAD AND TAPERED...
  • Page 74 Engine To be tightened Part No. Part Name Thread dia. Tightening Q’ty Remarks torque N•m pitch (kgf•m) HEAD x JOINT, 90110-06168 BOLT, M6 x 1.0 10±2 APPLY TO SCREW 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 75 Engine To be tightened Part No. Part Name Thread dia. Tightening Q’ty Remarks torque N•m pitch (kgf•m) Install OIL PUMP 95817-06035 BOLT, M6 x 1.0 10±2 FLANGE (1.0±0.2) ASSY. 95817-06025 BOLT, M6 x 1.0 10±2 FLANGE (1.0±0.2) Tighten DRAIN 90340-14019 PLUG, M14 x 1.5 23±2 STRAIGHT...
  • Page 76 Engine To be tightened Part No. Part Name Thread dia. Tightening Q’ty Remarks torque N•m pitch (kgf•m) Tighten together 90110-06389 BOLT, M6 x 1.0 10±2 APPLY TO SCREW HEXAGON (1.0±0.2) ROCKING with OIL PIPE SOCKET COMP. HEAD Tighten the cover 90110-06295 BOLT, M6 x 1.0...
  • Page 77 Engine To be tightened Part No. Part Name Thread dia. Tightening Q’ty Remarks torque N•m pitch (kgf•m) CHAMBER x 90110-08099 BOLT, M8 x 1.25 20±2 HEXAGON (2.0±0.2) SIDE STAND SOCKET CHAMBER x 90110-06343 BOLT, M6 x 1.0 10±2 HEXAGON (1.0±0.2) SILENCER SOCKET SILENCER x...
  • Page 78 Engine To be tightened Part No. Part Name Thread dia. Tightening Q’ty Remarks torque N•m pitch (kgf•m) CRANKCASE 1 95812-06050 BOLT, M6 x 1.0 10±2 APPLY OIL TO FLANGE (1.0±0.2) BOTH SCREW x CRANKCASE 2 THREAD AND BEARING. CRANKCASE 1 90105-06213 BOLT M6 x 1.0...
  • Page 79 Engine To be tightened Part No. Part Name Thread dia. Tightening Q’ty Remarks torque N•m pitch (kgf•m) Install DAMPER to 90149-06158 SCREW M6 x 1.0 10±2 APPLY TO SCREW (1.0±0.2) ROCKING COVER CRANK CASE 2 4H7-15189-00 PLUG M20 x 1.5 8±2 TAKE CARE PLUG for REAR (0.8±0.2)
  • Page 80 Engine To be tightened Part No. Part Name Thread dia. Tightening Q’ty Remarks torque N•m pitch (kgf•m) Tighten DRIVE 90179-22018 M22x 1.0 125±10 2 POINT SWAG- (12.5±1.0) ING AFTER SPROCKET TIGHTENING Install 90149-06158 SCREW M6 x 1.0 10±2 APPLY TO SCREW (1.0±0.2) ROCKING STOPPER,...
  • Page 81 Engine To be tightened Part No. Part Name Thread dia. Tightening Q’ty Remarks torque N•m pitch (kgf•m) Install OIL PRES- WS-82504-00 BOLT M4 x 0.7 1.5 – 2.0 accessory (0.15 – 0.2) SURE SWITCH LEAD WIRE 91312-06030 BOLT, M6 x 1.0 10±2 Install HEXAGON...
  • Page 82 Chassis Part No. Part Name Thread dia. Tightening Q’ty Remarks To be tightened torque N•m pitch (kgf•m) E/G BRACKET, 90110-12007 BOLT, M12 x 1.25 64 – 76 PROCEDURE HEXAGON (6.4 – 7.6) TO INSTALL FRONT, LEFT SOCKET THE ENGINE. FOR DETAILS, SEE page 87.
  • Page 83 Chassis Part No. Part Name Thread dia. Tightening Q’ty Remarks To be tightened torque N•m pitch (kgf•m) SHAFT, PIVOT 90185-20008 NUT, SELF M20 x 1.5 80 – 130 PROCEDURE LOCKING (8.0 – 13.0) TO INSTALL THE & U NUT PIVOT SHAFT PERIPHERAL PARTS.
  • Page 84 Chassis Part No. Part Name Thread dia. Tightening Q’ty Remarks To be tightened torque N•m pitch (kgf•m) HANDLE and 91380-06025 BOLT, M6 x 1.0 5 – 8 HEXAGON (0.5 – 0.8) HANDLE, SOCKET CROWN HEAD STEERING 90179-30691 M30 x 1.0 40 –...
  • Page 85 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 86 Tightening the Cylinder Head tightening of 10 N•m (1.0 kgf•m). additional tightening of 25 N•m (2.5 kgf•m). additional tightening of 45 N•m (4.5 kgf•m). 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 tightening operation one by one bolt.) The numbers 1 to 10 show the sequence...
  • Page 87 Installing the Crankcase 1. T i ghten t he b olt s in t he t ig htening 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 88 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 89 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 90 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 91 Procedure to install the pivot shaft peripheral parts 1. Tighten the pivot shaft 1 at specified torque. For information about tightening torque and requirement for lubricant agent, see 3. Tighten the nut 3 (self-rocking) at the list of tightening torque. Be sure to secure the pivot shaft 1 so that it is not co-rotated.
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  • Page 94 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 BLACK DARK_GRAY 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 B/L P/W Gy/R...
  • Page 95 Published by YAMAHA MOTOR ENGINEERING co., LTD...