Yamaha 2009 YZF-R1 (Y) Manuals

Yamaha 2009 YZF-R1 (Y) Manuals

Manuals and User Guides for Yamaha 2009 YZF-R1 (Y). We have 1 Yamaha 2009 YZF-R1 (Y) manual available for free PDF download: Service Manual

Yamaha 2009 YZF-R1 (Y) Service Manual

Yamaha 2009 YZF-R1 (Y) Service Manual (547 pages)

Brand: Yamaha | Category: Motorcycle | Size: 25.42 MB

Table of Contents

Important Manual Information
3
How to Use this Manual
4
Symbols
5
Table of Contents
7
General Information
9
Specifications
37
- General Specifications
  38
- Engine Specifications
  39
- Chassis Specifications
  46
- Electrical Specifications
  49
- General Tightening Torque Specifications
  52
- Tightening Torques
  52
- Engine Tightening Torques
  53
  - Connecting Rod Cap Bolt
    56
  - Crankcase Bolt (Main Journal)
    56
  - Cylinder Head Nut
    56
- Chassis Tightening Torques
  57
  - Front Wheel Axle Pinch Bolt
    59
  - Lower Bracket Pinch Bolt
    59
  - Lower Ring Nut
    59
- Engine
  61
- Lubrication Points and Lubricant Types
  61
- Chassis
  63
- Engine Oil Lubrication Chart
  64
- Lubrication System Chart and Diagrams
  64
- Lubrication Diagrams
  66
- Cooling System Diagrams
  82
- Cable Routing
  86
Periodic Checks and Adjustments
113
- Introduction
  116
- Periodic Maintenance Chart for the Emission Control System
  116
- General Maintenance and Lubrication Chart
  117
- Checking the Fuel Line (Primary Injector)
  119
- Checking the Fuel Line (Secondary Injector)
  119
- Checking the Spark Plugs
  119
- Adjusting the Valve Clearance
  120
  - Remove
    120
  - Measure
    121
  - Adjust
    123
- Valve Lapper
  123
  - Checking the Throttle Body Synchronization
    124
  - Install
    124
- Synchronizing the Throttle Bodies
  124
- Adjusting the Throttle Body Synchronization
  125
- Checking the Crankcase Breather Hose
  126
- Checking the Exhaust System
  126
- Checking the Throttle Body Joints
  126
- Adjusting the Exhaust Gas Volume
  127
- Checking the Air Induction System
  128
- Replacing the Air Filter Element
  128
- Adjusting the Clutch Cable Free Play
  129
  - Engine Side
    129
  - Handlebar Side
    129
- Checking the Brake Fluid Level
  130
- Checking the Brake Operation
  130
- Adjusting the Front Disc Brake
  131
- Adjusting the Rear Disc Brake
  131
- Checking the Front Brake Pads
  131
- Bleeding the Hydraulic Brake System
  132
- Checking the Rear Brake Pads
  132
- Checking the Front Brake Hoses
  133
- Checking the Rear Brake Hose
  134
- Checking the Tires
  134
- Checking the Wheels
  134
- Adjusting the Drive Chain Slack
  136
- Checking the Swingarm Operation
  136
- Checking the Wheel Bearings
  136
- Checking and Adjusting the Steering Head
  137
- Lubricating the Drive Chain
  137
- Adjusting the Shift Pedal
  138
- Checking the Chassis Fasteners
  138
- Checking the Steering Damper
  138
- Lubricating the Clutch Lever
  138
- Lubricating the Pedal
  138
- Adjusting the Front Fork Legs
  139
- Checking the Front Fork
  139
- Checking the Sidestand Switch
  139
- Lubricating the Sidestand
  139
  - Rebound Damping
    140
  - Spring Preload
    140
- Adjusting the Rear Shock Absorber Assembly
  141
- Checking the Connecting Arm and Relay Arm
  143
- Checking the Engine Oil Level
  143
- Changing the Engine Oil
  144
- Measuring the Engine Oil Pressure
  145
- Oil Pressure Adapter H
  145
- Checking the Coolant Level
  146
- Checking the Cooling System
  146
- Changing the Coolant
  147
- Adjusting the Rear Brake Light Switch
  148
- Checking and Lubricating the Cables
  148
- Adjusting the Throttle Cable Free Play
  149
- Checking and Charging the Battery
  149
- Checking the Fuses
  149
- Lubricating the Rear Suspension
  149
- Replacing the Headlight Bulbs
  149
- Adjusting the Headlight Beams
  150
Chassis
153
- General Chassis
  156
- Removing the Seats and Battery
  156
- Removing the Side Cowlings
  157
- Removing the ECU and Rectifier/Regulator
  158
- Removing the Air Ducts
  159
- Removing the Front Cowling Assembly
  160
- General Chassis
  160
- Removing the Meter and Headlight
  161
- Disassembling the Headlight Assembly
  163
- Removing the Rear Fender
  164
- Disassembling the License Plate/Turn Signal Light Assembly
  165
- Removing the Quick Fastener (Pull Type)
  166
- Removing and Installing the Quick Fastener (Push Type)
  166
- Removing and Installing the Quick Fastener (Screw Type)
  166
- Installing the Passenger Seat Lock Cylinder
  167
- Removing and Installing the Front Turn Signal Lights
  167
- Installing the Quick Fastener (Pull Type)
  167
- Removing and Installing the Lower Cowlings
  168
- Removing and Installing the Side Cowling Inner Panels
  168
- Removing the Air Chamber Covers
  168
- Installing the Air Chamber Covers
  169
- Removing and Installing the Intake Air Duct Covers
  169
- Installing the Air Intake Ducts
  169
- Installing the Rear View Mirrors
  169
- Removing the Upper Tail Cover
  170
- Removing the Windshield
  170
- Installing the Mirror Fitting Plates
  170
- Installing the Windshield
  170
- Installing the Upper Tail Cover
  171
- Installing the Tail/Brake Light
  171
- Adjusting the Rider Footrests
  171
- Removing the Front Wheel and Brake Discs
  173
- Disassembling the Front Wheel
  174
- Removing the Front Wheel
  175
- Checking the Front Wheel
  175
- Adjusting the Front Wheel Static Balance
  176
- Installing the Front Wheel
  177
- Removing the Rear Wheel
  179
- Removing the Brake Disc and Rear Wheel Sprocket
  180
- Disassembling the Rear Wheel
  181
- Checking the Rear Wheel
  182
- Checking the Rear Wheel Drive Hub
  183
- Checking and Replacing the Rear Wheel Sprocket
  183
- Adjusting the Rear Wheel Static Balance
  183
- Installing the Rear Wheel
  183
- Removing the Front Brake Pads
  185
- Removing the Front Brake Master Cylinder
  186
- Disassembling the Front Brake Master Cylinder
  187
- Removing the Front Brake Calipers
  188
- Disassembling the Front Brake Calipers
  189
- Checking the Front Brake Discs
  190
- Replacing the Front Brake Pads
  191
- Checking the Front Brake Calipers
  193
- Assembling the Front Brake Calipers
  194
- Installing the Front Brake Calipers
  194
- Checking the Front Brake Master Cylinder
  195
- Assembling the Front Brake Master Cylinder
  196
- Installing the Front Brake Master Cylinder
  196
- Removing the Rear Brake Pads
  198
- Removing the Rear Brake Master Cylinder
  199
- Disassembling the Rear Brake Master Cylinder
  200
- Removing the Rear Brake Calipers
  201
- Disassembling the Rear Brake Caliper
  202
- Checking the Rear Brake Disc
  203
- Replacing the Rear Brake Pads
  203
- Removing the Rear Brake Caliper
  205
- Checking the Rear Brake Caliper
  205
- Assembling the Rear Brake Caliper
  206
- Installing the Rear Brake Caliper
  206
- Checking the Rear Brake Master Cylinder
  207
- Installing the Rear Brake Master Cylinder
  208
- Assembling the Rear Brake Master Cylinder
  208
- Removing the Handlebars
  210
- Removing the Handlebar
  212
- Checking the Handlebars
  212
- Installing the Handlebars
  212
- Removing the Front Fork Legs
  214
- Disassembling the Front Fork Legs
  215
- Front Fork
  217
- Checking the Front Fork Legs
  219
- Assembling the Front Fork Legs
  219
- Installing the Front Fork Legs
  223
- Steering Head
  225
- Removing the Lower Bracket
  225
- Checking the Steering Head
  227
- Installing the Steering Head
  228
- Checking the Steering Damper
  228
- Removing the Rear Shock Absorber Assembly
  229
- Handling the Rear Shock Absorber
  230
- Disposing of a Rear Shock Absorber
  230
- Checking the Rear Shock Absorber Assembly
  230
- Checking the Connecting Arm and Relay Arm
  231
- Installing the Relay Arm
  231
- Installing the Rear Shock Absorber Assembly
  231
- Removing the Swingarm
  233
- Checking the Swingarm
  236
- Installing the Swingarm
  236
- Removing the Drive Sprocket and Drive Chain
  238
- Removing the Drive Chain
  239
- Checking the Drive Chain
  239
- Checking the Drive Sprocket
  240
- Installing the Drive Chain
  240
Engine
243
- Engine Inspection
  246
- Measuring the Compression Pressure
  246
- Engine Removal
  248
  - Removing the Exhaust Pipe and Muffler
    248
  - Disconnecting the Leads and Hoses
    251
  - Removing the Engine
    253
- Installing the Engine
  255
- Pivot Shaft Wrench Adapter
  255
- Installing the Exhaust Pipe and Muffler
  256
- Camshafts
  258
  - Removing the Cylinder Head Cover
    258
  - Removing the Camshafts
    260
- Removing the Camshafts
  262
- Checking the Camshafts
  263
- Checking the Timing Chain and Sprocket
  264
- Checking the Timing Chain Guides
  265
- Checking the Timing Chain Tensioner
  265
- Installing the Camshafts
  265
- Removing the Cylinder Head
  270
- Checking the Cylinder Head
  271
- Installing the Cylinder Head
  271
- Removing the Valves and Valve Springs
  273
- Removing the Valves
  275
- Valves and Valve Springs
  275
- Checking the Valves and Valve Guides
  276
- Checking the Valve Seats
  277
- Checking the Valve Springs
  279
- Checking the Valve Lifters
  280
- Installing the Valves
  280
- Removing the Generator
  282
- Installing the Generator
  283
- Removing the Generator
  283
- Removing the Starter Clutch
  285
- Checking the Starter Clutch
  286
- Installing the Starter Clutch
  286
- Removing the Pickup Rotor
  288
- Installing the Pickup Rotor
  289
- Electric Starter
  291
  - Removing the Starter Motor
    291
  - Disassembling the Starter Motor
    292
- Checking the Starter Motor
  293
- Assembling the Starter Motor
  294
  - Removing the Oil Pan and Oil/Water Pump Assembly
    296
  - Disassembling the Oil Pump
    298
- Checking the Oil Pump
  299
- Checking the Sprocket and Chain
  299
- Removing the Oil Pan
  299
- Checking the Oil Delivery Pipes
  300
- Checking the Oil Strainer
  300
- Checking the Relief Valve
  300
- Assembling the Oil Pump
  301
- Installing the Oil/Water Pump Assembly
  301
- Installing the Oil Pan
  302
  - Removing the Clutch Cover
    304
  - Removing the Pull Lever Shaft
    305
  - Removing the Clutch
    306
- Removing the Clutch
  308
- Checking the Clutch Plates
  309
- Checking the Friction Plates
  309
- Checking the Clutch Boss
  310
- Checking the Clutch Housing
  310
- Checking the Clutch Springs
  310
- Checking the Pressure Plate
  311
- Checking the Primary Driven Gear
  311
- Checking the Pull Lever Shaft and Pull Rod
  311
- Installing the Clutch
  311
- Removing the Shift Shaft and Stopper Lever
  314
- Checking the Shift Shaft
  315
- Checking the Stopper Lever
  315
- Installing the Shift Shaft
  315
- Separating the Crankcase
  316
- Assembling the Crankcase
  318
- Checking the Crankcase
  318
- Disassembling the Crankcase
  318
- Removing the Connecting Rods and Pistons
  320
- Checking the Cylinder and Piston
  321
- Connecting Rods and Pistons
  321
- Removing the Connecting Rods and Pistons
  321
- Checking the Piston Rings
  322
- Checking the Piston Pin
  323
- Checking the Connecting Rods
  324
- Installing the Connecting Rod and Piston
  327
- Removing the Crankshaft
  331
- Checking the Crankshaft
  332
- Checking the Oil Nozzles
  332
- Removing the Crankshaft and Balancer Shaft
  332
- Checking the Balancer Shaft
  334
- Installing the Crankshaft
  335
- Installing the Balancer Assembly
  336
- Checking the Shift Forks
  341
- Removing the Transmission
  341
- Checking the Shift Drum Assembly
  342
- Checking the Transmission
  342
- Assembling the Main Axle and Drive Axle
  343
- Installing the Transmission
  343
Cooling System
345
- Removing the Radiator
  346
- Checking the Radiator
  348
- Installing the Radiator
  348
- Removing the Oil Cooler
  350
- Checking the Oil Cooler
  352
- Installing the Oil Cooler
  352
- Removing the Thermostat
  353
- Checking the Thermostat
  355
- Assembling the Thermostat Assembly
  355
- Installing the Thermostat Assembly
  356
- Disassembling the Water Pump
  357
- Assembling the Water Pump
  358
- Checking the Water Pump
  358
Fuel System
361
Electrical System
389
Troubleshooting
537
- Incorrect Engine Idling Speed
  538
- Starting Failures
  538
- Poor Medium-And-High-Speed Performance
  539
- Jumps out of Gear
  539
- Faulty Clutch
  539
- Overheating
  539
- Poor Braking Performance
  540
- Faulty Front Fork Legs
  540
- Unstable Handling
  540
- Faulty Lighting or Signaling System
  541
- Wiring Diagram YZF-R1(Y)
  542
- Color Code
  542

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