Yamaha 2006 YSF-R1(V) Supplementary Service Manual
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Yamaha 2006 YSF-R1(V) Supplementary Service Manual

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2006
YZF-R1(V)
YZF-R1S(V)
5VY-28197-E2
SUPPLEMENTARY
SERVICE MANUAL

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Summary of Contents for Yamaha 2006 YSF-R1(V)

  • Page 1 2006 YZF-R1(V) YZF-R1S(V) 5VY-28197-E2 SUPPLEMENTARY SERVICE MANUAL...
  • Page 3 Supplementary Service Manual together with the following manual. YZF-R1 (S) 2004 SERVICE MANUAL: 5VY1-AE1 YZF-R1 (V) / YZF-R1S (V) 2006 SUPPLEMENTARY SERVICE MANUAL ©2005 by Yamaha Motor Co., Ltd. First Edition, October 2005 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Co., Ltd.

  • Page 4: Important Manual Information

    EAS00002 NOTICE This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha deal- ers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles should have a basic understanding of mechanics and the techniques to repair these types of vehicles.

  • Page 5: How To Use This Manual

    EAS00007 HOW TO USE THIS MANUAL This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid out with the individual steps in sequential order. The manual is divided into chapters.
  • Page 6 EAS00008 SYMBOLS The following symbols are not relevant to every vehicle. Symbols indicate the subject of each chapter. General information Specifications Periodic checks and adjustments Chassis Engine Cooling system Fuel injection system Electrical system Troubleshooting Symbols indicate the following. Serviceable with engine mounted Filling fluid Lubricant Special tool...

  • Page 7: Table Of Contents

    CONTENTS GENERAL INFORMATION SPECIAL TOOLS ........SPECIFICATIONS GENERAL SPECIFICATIONS .
  • Page 8 ENGINE ENGINE ..........INSTALLING THE ENGINE .

  • Page 9: General Information

    SPECIAL TOOLS INFO EAS00027 GENERAL INFORMATION SPECIAL TOOLS The following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools as this will help prevent damage caused by the use of inappropri- ate tools or improvised techniques. Special tools, part numbers or both may differ depending on the country.

  • Page 10: Specifications

    SPEC GENERAL SPECIFICATIONS SPECIFICATIONS GENERAL SPECIFICATIONS Item Standard Limit Model code YZF-R1 5VYE (EUR), 5VYR (EUR), 5VYF (FRA), • • • 5VYS (FRA), 5VYG (AUS), 5VYP (AUS) YZF-R1S 4B11 (EUR), 4B12 (FRA), 4B13 (AUS) • • • Dimensions Overall length 2,085 mm (82.1 in) •...

  • Page 11: Engine Specifications

    SPEC ENGINE SPECIFICATIONS ENGINE SPECIFICATIONS Item Standard Limit Engine oil Recommended oil SAE10W30SE or SAE10W40SE or SAE15W40SE or SAE20W40SE or SAE20W50SE API service SE, SF, SG type or higher Oil pump Oil-pump-housing-to-inner-and-outer- 0.06 ~ 0.13 mm 0.20 mm rotor clearance (0.0024 ~ 0.0051 in) (0.0079 in) Cylinder head...
  • Page 12 SPEC ENGINE SPECIFICATIONS Item Standard Limit Clutch Friction plates Color code • • • Thickness 2.9 ~ 3.1 mm (0.114 ~ 0.122 in) 2.8 mm (0.110 in) Plate quantity • • • Color code • • • Thickness 2.9 ~ 3.1 mm (0.114~ 0.122 in) 2.8 mm (0.110 in) Plate quantity...

  • Page 13: Chassis Specifications

    SPEC CHASSIS SPECIFICATIONS CHASSIS SPECIFICATIONS Item Standard Limit Front wheel Wheel type Forged wheel (YZF-R1S) • • • Rear wheel Wheel type Forged wheel (YZF-R1S) • • • Front tire Model(manufacturer) Pilot POWER (MICHELIN) (YZF-R1) • • • D218FG (DUNLOP) (YZF-R1) •...
  • Page 14 SPEC CHASSIS SPECIFICATIONS Item Standard Limit Front suspension (YZF-R1) Fork oil Quantity (each front fork leg) 0.52 L (0.46 Imp qt, 0.55 US qt) • • • Level (from the top of the outer tube, 90 mm (3.54 in) • • • with the outer tube fully compressed, and without the fork spring) Spring preload adjusting positions...
  • Page 15 SPEC CHASSIS SPECIFICATIONS Item Standard Limit Rear suspension (YZF-R1) Spring preload adjusting positions Minimum • • • Standard • • • Maximum • • • (YZF-R1S) Spring Free length 150.0 mm (5.91 in) • • • Installed length 139.0 mm (5.47 in) •...

  • Page 16: Electrical Specifications

    SPEC ELECTRICAL SPECIFICATIONS / TIGHTENING TORQUES ELECTRICAL SPECIFICATIONS Item Standard Limit Ignition system T.C.I. unit model (manufacturer) F8T82073 (MITSUBISHI) (EUR, AUS) • • • F8T82074 (MITSUBISHI) (FRA) • • • Battery Manufacturer GS-YUASA • • • Ten hour rate amperage 0.9 A •...

  • Page 17: Chassis Tightening Torques

    SPEC TIGHTENING TORQUES CHASSIS TIGHTENING TORQUES Tightening Thread Item Remarks size m•kg ft•lb Horn bracket and under bracket Connecting rod (YZF-R1S) Side cover and fuel tank Front fork and stay (YZF-R1S) Front fork and bracket (YZF-R1S) Rear brake master cylinder and foot rest bracket Front brake disc and front wheel (YZF-R1S) Front wheel axle pinch bolt (YZF-R1S) See NOTE...

  • Page 18: Lubrication Points And Lubricant Types

    SPEC LUBRICATION POINTS AND LUBRICANT TYPES EAS00031 LUBRICATION POINTS AND LUBRICANT TYPES ENGINE Lubrication point Lubricant Valve lifter surfaces (intake and exhaust) Valve stem ends (intake and exhaust) EAS00032 CHASSIS Lubrication point Lubricant Pivot shaft...

  • Page 19: Lubrication Diagrams

    SPEC LUBRICATION DIAGRAMS LUBRICATION DIAGRAMS Main axle Oil delivery pipe Drive axle...

  • Page 20: Cable Routing

    SPEC CABLE ROUTING EAS00035 CABLE ROUTING Insert to the rib of the head Connect after passing over the Ground lead Meter lead light. (Either location of the right upper side of the duct. Stay 1 and left relays is acceptable.) Clamp the head light lead by Auxiliary light lead (right) The lead should not stretch too...
  • Page 21 SPEC CABLE ROUTING There should 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.
  • Page 22 SPEC CABLE ROUTING Right handlebar switch lead Route the clutch cable so as to Clamp the leads inside the front Clutch cable get along the front side of the fork of the vehicle. Point the exit main switch after passing it of the horn lead to the left front Main switch lead Left handlebar switch lead...
  • Page 23 SPEC CABLE ROUTING Contact the wire guide to the top face of the under bracket boss. The throttle cable should not be 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.
  • Page 24 SPEC CABLE ROUTING Wire harness Clamp it after passing between Clamp the clamp upper end Crankshaft position sensor lead the frame and radiator stay. along the line of lower end of Point the tip of the clamp the hose clamp assembly. Point Heat protector Right handlebar switch lead (excessive part) to the front side...
  • Page 25 SPEC CABLE ROUTING The coupler for the air induction Coolant reservoir tank drain Release the tip of the clamp and solenoid lead and camshaft hose should cross with the install it to the clutch cable. speed sensor lead under the Insert the clamp to the hole sensor lead should be con- nected above the ignition coil...
  • Page 26 SPEC CABLE ROUTING Heat protector Clamp the leads so that they Pass the main switch lead, left Main switch lead are positioned inner of the vehi- handlebar switch lead cle than the washer position immobilizer lead between the Left handlebar switch lead Immobilizer lead after routing them between the frame and the heat protector.
  • Page 27 SPEC CABLE ROUTING Pass the coolant reservoir tank Route the lead by the inside of Route the water hose so that it drain hose and fuel tank drain the water hose and water pipe. is placed at the outermost posi- There should be no exposure of tion finally after routing other hose through the clamp from...
  • Page 28 SPEC CABLE ROUTING Routing of the fuel tank drain hose. EXUP servo motor, oil level switch and sidestand switch leads are omitted in this draw- ing.
  • Page 29 SPEC CABLE ROUTING Heat protector Battery negative lead Thermo stat assembly breather Crankshaft position sensor lead Starter motor lead hose A.C.magneto lead Throttle body side cap Neutral switch lead Ground lead Oil level switch lead Mud guard Coolant reservoir tank Sidestand switch lead Turn signal light lead Battery positive lead...
  • Page 30 SPEC CABLE ROUTING Main fuse lead (To the battery Pass the wire harness through Point the tip of the clamp positive lead) the clamp inserted to the radia- (excessive part) to the inside of the vehicle. Right handlebar switch lead tor stay.
  • Page 31 SPEC CABLE ROUTING Pass the water hose lower side Pass the lead through inside of Make sure to position the cou- of the thermostat, and between the battery band. pler at the downmost position of Press on the tip of the clamp leads.
  • Page 32 SPEC CABLE ROUTING Point the tip of the clamp Point the tip of the clamp Fasten wire harness, (excessive part) to the rear side (excessive part) to the down A.C.magneto lead, and throt- side of the vehicle. Fasten the tle body lead with a clamp. of the vehicle.
  • Page 33 SPEC CABLE ROUTING Insert the wire harness wrap- Do not place it beyond pipe 3 Route the leads in random ping clamp to the hole of the in the direction to the external order. part of the vehicle. frame. Make sure that the lead is fas- Route each lead higher than tened with the guide of the the frame plate, pass it to the...
  • Page 34 SPEC CABLE ROUTING Fuel tank Install the lip of O-ring facing Fuel piping connector attach- O-ring upward. ment directions. (fuel pump side) Install the part pointing the Always use hands to connect / Fuel tank drain hose Fuel tank breather hose white paint part of the hose to disconnect the connector with- Clip...
  • Page 35 SPEC CABLE ROUTING 2. After Item 1 mentioned above is finished, check that the clamp is inserted from the down side, -sections are perfectly equipped.

  • Page 36: Periodic Checks And Adjustments

    • From 50,000 km, repeat the maintenance intervals starting from 10,000 km. • Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills. ODOMETER READING (× 1,000 km)
  • Page 37 PERIODIC MAINTENANCE AND LUBRICATION INTERVALS ODOMETER READING (× 1,000 km) ANNUAL ITEM CHECK OR MAINTENANCE JOB CHECK Rear suspension relay √ √ √ √ arm and connecting arm • Check operation. pivoting points √ √ √ √ √ √ Fuel injection •...

  • Page 38: Chassis

    ADJUSTING THE FRONT FORK LEGS EAS00155 CHASSIS ADJUSTING THE FRONT FORK LEGS (YZF-R1S) The following procedure applies to both of the front fork legs. WARNING • Always adjust both front fork legs evenly. Uneven adjustment can result in poor han- dling and loss of stability.
  • Page 39 ADJUSTING THE FRONT FORK LEGS NOTE: NOTE: To find the standard position, turn the adjusting bolt in direction 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 adjusting bolt in direction until the alignment marks match.
  • Page 40 ADJUSTING THE FRONT FORK LEGS Compression damping CAUTION: Never go beyond the maximum or minimum adjustment positions. 1. Adjust: • compression damping a. Turn the adjusting screw in direction Compression damping is Direction increased (suspension is harder). Compression damping is Direction decreased (suspension is softer).

  • Page 41: Adjusting The Rear Shock Absorber Assembly

    ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY EAS00158 ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY (YZF-R1S) WARNING Securely support the vehicle so that there is no danger of it falling over. Spring preload CAUTION: Never go beyond the maximum or minimum adjustment positions. 1.
  • Page 42 ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY 1. Adjust: • rebound damping a. Turn the adjusting screw in direction Rebound damping is Direction increased (suspension is harder). Rebound damping is Direction 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...
  • Page 43 ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY Compression damping (slow compression damping) CAUTION: Never go beyond the maximum or minimum adjustment positions. 1. Adjust: • slow compression damping a. Turn the adjusting screw in direction Compression damping is Direction increased (suspension is harder).

  • Page 44: Chassis

    CHAS FRONT WHEEL AND BRAKE DISCS EAS00514 CHASSIS FRONT WHEEL AND BRAKE DISCS (YZF-R1S) 6 Nm (0.6 m•kg, 4.3 ft•lb) 35 Nm (3.5 m•kg, 25 ft•lb) 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) 23 Nm (2.3 m•kg, 17 ft•lb) Order Job / Part...

  • Page 45: Rear Wheel And Brake Discs

    CHAS REAR WHEEL AND BRAKE DISCS EAS00560 REAR WHEEL AND BRAKE DISCS REAR BRAKE DISC AND REAR WHEEL SPROCKET (YZF-R1S) 30 Nm (3.0 m•kg, 22 ft•lb) 100 Nm (10 m•kg, 72 ft•lb) Order Job / Part Q’ty Remarks Removing the rear brake disc and Remove the parts in the order listed.
  • Page 46 CHAS REAR WHEEL AND BRAKE DISCS (YZF-R1S) Order Job / Part Q’ty Remarks Disassembling the rear wheel Disassemble the parts in the order listed. Collar Bearing Spacer Oil seal Bearing For assembly, reverse the disassembly procedure.

  • Page 47: Front Fork

    CHAS FRONT FORK EAS00648 FRONT FORK FRONT FORK LEGS (YZF-R1S) 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) Order Job / Part Q’ty Remarks Disassembling the front fork legs Disassemble the parts in the order listed.
  • Page 48 CHAS FRONT FORK (YZF-R1S) 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) Order Job / Part Q’ty Remarks Spring guide Spring seat Dust seal Oil seal clip Oil seal Washer...

  • Page 49: Disassembling The Front Fork Legs

    CHAS FRONT FORK EAS00652 DISASSEMBLING THE FRONT FORK LEGS (YZF-R1S) The following procedure applies to both of the front fork legs. 1. Remove: • fork stay • fork bracket • cap bolt (from the damper adjusting rod) a. Press down on the spacer with the fork spring compressor b.
  • Page 50 CHAS FRONT FORK 4. Remove: • dust seal • oil seal clip • oil seal • washer (with a flat-head screwdriver) CAUTION: Do not scratch the inner tube. 5. Remove: • spring 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.

  • Page 51: Checking The Front Fork Legs

    CHAS FRONT FORK EAS00656 CHECKING THE FRONT FORK LEGS (YZF-R1S) 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.

  • Page 52: Assembling The Front Fork Legs

    CHAS FRONT FORK EAS00659 ASSEMBLING THE FRONT FORK LEGS (YZF-R1S) The following procedure applies to both of the front fork legs. WARNING • Make sure the oil levels in both front fork legs are equal. • Uneven oil levels can result in poor han- dling and a loss of stability.
  • Page 53 CHAS FRONT FORK 4. Install: • dust seal • oil seal clip • oil seal • washer CAUTION: Make sure the numbered side of the oil seal faces up. NOTE: NOTE: • Before installing the oil seal, lubricate its lips with lithium-soap-based grease.
  • Page 54 CHAS FRONT FORK 7. Install: • dust seal (with the fork seal driver weight Fork seal driver 90890-01442, YM-01442 8. Install: • rod puller • rod puller attachment (onto the damper rod Rod puller 90890-01437, YM-A8703 Rod puller attachment 90890-01435, YM-A8703 9.
  • Page 55 CHAS FRONT FORK 10.Install: • spring seat • spring guide • spacer • clip • fork spring • spring seat (upper) • nut • damper adjusting rod • cap bolt • fork bracket • fork stay a. Install the spring seat, spring guide, spacer and circlip.

  • Page 56: Rear Shock Absorber Assembly

    CHAS REAR SHOCK ABSORBER ASSEMBLY EAS00685 REAR SHOCK ABSORBER ASSEMBLY (YZF-R1S) 44 Nm (4.4 m•kg, 32 ft•lb) 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) Order Job/Part Q’ty Remarks Removing the rear shock absorber Remove the parts in the order listed.
  • Page 57 CHAS REAR SHOCK ABSORBER ASSEMBLY (YZF-R1S) 44 Nm (4.4 m•kg, 32 ft•lb) 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) Order Job / Part Q’ty Remarks Relay arm For installation, reverse the removal procedure.

  • Page 58: Removing The Rear Shock Absorber Assembly

    CHAS REAR SHOCK ABSORBER ASSEMBLY EAS00690 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY (YZF-R1S) 1. Stand the vehicle on a level surface. WARNING Becurely support the vehicle so that there is no danger of it falling over. NOTE: NOTE: Place the vehicle on a suitable stand so that the rear wheel is elevated.

  • Page 59: Installing The Rear Shock Absorber Assembly

    CHAS REAR SHOCK ABSORBER ASSEMBLY EAS00698 INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY (YZF-R1S) 1. Lubricate: • spacers • bearings Recommended lubricant Lithium – soap-based grease 2. Check: • connecting rod assembly Refer to “CHECKING THE CONNECTING ROD ASSEMBLY” 3. Install: •...

  • Page 60: Swingarm And Drive Chain

    CHAS SWINGARM AND DRIVE CHAIN EAS00703 SWINGARM AND DRIVE CHAIN REMOVING THE SWINGARM (YZF-R1S) 1. Stand the vehicle on a level surface. WARNING Securely support the vehicle so that there is no danger of it falling over. NOTE: NOTE: Place the vehicle on a suitable stand so that the rear wheel is elevated.

  • Page 61: Checking The Swingarm

    CHAS SWINGARM AND DRIVE CHAIN EAS00707 CHECKING THE SWINGARM (YZF-R1S) 1. Check: • swingarm Bends / cracks / damage → Replace. 2. Check: • pivot shaft Roll the pivot shaft on a flat surface. Bends → Replace. WARNING Do not attempt to straighten a bent pivot shaft.

  • Page 62: Checking The Connecting Rod Assembly

    CHAS SWINGARM AND DRIVE CHAIN CHECKING THE CONNECTING ROD ASSEMBLY 1. Check: • connecting rod assembly Bends / damage → Replace the connecting rod assembly • oil seal Damage/wear → Replace • bearing Damage/wear → Replace 2. Measure: • connecting rod assembly length Out of specification →...

  • Page 63: Checking The Drive Chain

    CHAS SWINGARM AND DRIVE CHAIN EAS00709 CHECKING THE DRIVE CHAIN 1. Measure: • Measure the dimension between 15-links on the inner side and outer side the roller and calculate the dimension between pin centers. • Dimension between pin centers = (Inner dimension + Outer dimension ) / 2...
  • Page 64 CHAS SWINGARM AND DRIVE CHAIN CAUTION: This vehicle has a drive chain with small rubber O-rings between the drive chain side plates. Never use high-pressure water or air, steam, gasoline, certain solvents (e.g., benzine), or a coarse brush to clean the drive chain.

  • Page 65: Engine

    ENGINE ENGINE ENGINE 45 Nm (4.5 m•kg, 33 ft•lb) 51 Nm (5.1 m•kg, 37 ft•lb) YZF-R1S 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) Order Job / Part Q’ty Remarks Removing the engine Remove the parts in the order listed.
  • Page 66 ENGINE 45 Nm (4.5 m•kg, 33 ft•lb) 51 Nm (5.1 m•kg, 37 ft•lb) YZF-R1S 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) Order Job / Part Q’ty Remarks Upper engine mounting bolt Engine mounting adjust bolt NOTE: NOTE:...

  • Page 67: Installing The Engine

    ENGINE INSTALLING THE ENGINE 1. Install: • engine mounting adjust bolts (temporary tighten) 2. Install: • engine 3. Install: • lower engine mounting bolt • upper engine mounting bolt • self locking nuts NOTE: NOTE: Lubricate the lower and upper engine mount- ing bolts threads with lithium-soap-based grease.
  • Page 68 ENGINE Pivot shaft wrench 90890-01471, YM-01471 Pivot shaft wrench adapter 90890-01476 7. Tighten: • upper self-locking nut • lower self-locking nut 51 Nm (5.1 m•kg, 37 ft•lb) NOTE: NOTE: First tighten the lower self-locking nut, and then tighten the upper self-locking nut. 8.

  • Page 69: Camshafts

    ENGINE EAS00196 CAMSHAFTS 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, 7.2 ft•lb) Order Job / Part Q’ty Remarks Removing the camshafts Remove the parts in the order listed.

  • Page 70: Clutch

    CLUTCH CLUTCH CLUTCH COVER 12 Nm (1.2 m•kg, 8.7 ft•lb) 12 Nm (1.2 m•kg, 8.7 ft•lb) 10 Nm (1.0 m•kg, 7.2 ft•lb) Order Job / Part Q’ty Remarks Removing the clutch cover Remove the parts in the order listed. Right side cowling Right frame side cover Refer to “COWLINGS”...

  • Page 71: Clutch

    CLUTCH CLUTCH (YZF-R1) 95 Nm (9.5 m•kg, 69 ft•lb) 10 Nm (1.0 m•kg, 7.2 ft•lb) Order Job / Part Q’ty Remarks Removing the clutch Remove the parts in the order listed. Compression spring Pressure plate Pull rod Bearing Friction plate 1 Clutch plate 1 Friction plate 2 Wire clip...
  • Page 72 CLUTCH (YZF-R1) 95 Nm (9.5 m•kg, 69 ft•lb) 10 Nm (1.0 m•kg, 7.2 ft•lb) Order Job / Part Q’ty Remarks Clutch boss nut Washer Thrust plate 1 Clutch boss Thrust plate 2 Clutch housing Bearing For installation, reverse the removal procedure.
  • Page 73 CLUTCH (YZF-R1S) 95 Nm (9.5 m•kg, 69 ft•lb) 10 Nm (1.0 m•kg, 7.2 ft•lb) Order Job / Part Q’ty Remarks Removing the clutch Remove the parts in the order listed. Compression spring Pressure plate 1 Pull rod Bearing Friction plate 1 Clutch plate 1 Friction plate 2 Clutch plate 2...
  • Page 74 CLUTCH (YZF-R1S) 95 Nm (9.5 m•kg, 69 ft•lb) 10 Nm (1.0 m•kg, 7.2 ft•lb) Order Job / Part Q’ty Remarks Spring Clutch boss Pressure plate 2 Conical spring washer Thrust plate 2 Clutch housing Bearing For installation, reverse the removal procedure.

  • Page 75: Removing The Clutch

    CLUTCH EAS00276 REMOVING THE CLUTCH (YZF-R1S) 1. Remove: • clutch cover • gasket NOTE: NOTE: Loosen each bolt 1 / 4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them.

  • Page 76: Checking The Friction Plates

    CLUTCH 6. Loosen: • clutch boss nut NOTE: NOTE: While holding the clutch boss with the uni- versal clutch holder , loosen the clutch boss nut. Universal clutch holder 90890-04086, YM-91042 7. Remove: • clutch boss nut • springs • clutch boss •...

  • Page 77: Checking The Clutch Plates

    CLUTCH EAS00281 CHECKING THE CLUTCH PLATES (YZF-R1S) The following procedure applies to all of the clutch plates. 1. Check: • clutch plate Damage → Replace the clutch plates as a set. 2. Measure: • clutch plate warpage (with a surface plate and thickness gauge Out of specification →...

  • Page 78: Checking The Clutch Springs

    CLUTCH NOTE: NOTE: When adjusting the clutch assembly width [by replacing the clutch plate(s)], be sure to replace the clutch plate fast. After replacing the clutch plate , if specifica- tions cannot be met, replace the clutch plate EAS00282 CHECKING THE CLUTCH SPRINGS (YZF-R1S) The following procedure applies to all of the clutch springs.

  • Page 79: Checking The Pressur Plate 2

    CLUTCH CHECKING THE PRESSUR PLATE 2 (YZF-R1S) 1. Check: • pressure plate 2 Cracks / damage → Replace. EAS00285 CHECKING THE CLUTCH BOSS (YZF-R1S) 1. Check: • clutch boss splines Damage / pitting / wear → Replace the clutch boss. NOTE: NOTE: Pitting on the clutch boss splines will cause...

  • Page 80: Checking The Pull Lever Shaft And Pull Rod

    CLUTCH EAS00287 CHECKING THE PULL LEVER SHAFT AND PULL ROD (YZF-R1S) 1. Check: • pull lever shaft pinion gear teeth • pull rod teeth Damage / wear → Replace the pull rod and pull lever shaft pinion gear as a set. 2.
  • Page 81 CLUTCH 3. Install: • spring • clutch boss nut 95 Nm (9.5 m•kg, 69 ft•lb) NOTE: NOTE: • Put the spring detent into the groove of the pressure plate 2. Assemble so that each spring detent positioned in a different groove. •...
  • Page 82 CLUTCH 6. Install: • friction plate 3 • friction plate 2 • clutch plate 3 • clutch plate 2 • clutch plate 1 NOTE: NOTE: Assemble the friction plates and clutch plates according to the installation order. 7. Install: • friction plate 1 NOTE: NOTE: Install the last friction plate shifting half phase.
  • Page 83 CLUTCH 10.Install: • pull lever NOTE: NOTE: Install the pull lever with the “ ” mark facing toward upper side. 11.Install: • clutch cover • clutch cover gasket NOTE: NOTE: • Install the pull rod so that the teeth a face towards the rear of the vehicle.

  • Page 84: Yzf-R1 (V) / Yzf-R1S (V) 2006 Wiring Diagram

    YZF-R1 (V)/ COLOR CODE Engine stop switch B..Black YZF-R1S (V) 2006 Start switch Br ..Brown Turn signal relay WIRING DIAGRAM Ch ..Chocolate Left handlebar switch Main switch Dg .
  • Page 86 YAMAHA MOTOR CO., LTD. 2500 SHINGAI IWATA SHIZUOKA JAPAN...
  • Page 87 YZF-R1 (V)/YZF-R1S (V) 2006 YZF-R1 (V)/YZF-R1S (V) 2006 YZF-R1 (V)/YZF-R1S (V) YZF-R1 (V)/YZF-R1S (V) 2006 DIAGRAMA DE CONEXIONES WIRING DIAGRAM SCHEMA DE CABLAGE SCHALTPLAN 2006 SCHEMA ELETTRICO DE YZF-R1 (V)/YZF-R1S (V) 2006 R/L R/B G/B O/G R/B O Gy/R Gy/R Dg L/R L/W R/G Y/L B/W G/W...

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