Yamaha YZF-R1M 2015 Manuals

Manuals and User Guides for Yamaha YZF-R1M 2015. We have 1 Yamaha YZF-R1M 2015 manual available for free PDF download: Service Manual

Yamaha YZF-R1M 2015 Service Manual

Yamaha YZF-R1M 2015 Service Manual (705 pages)

Brand: Yamaha | Category: Motorcycle | Size: 42.2 MB

Table of Contents

How to Use this Manual
5
Symbols
6
Table of Contents
7
General Information
9
- Model Label
  10
- Vehicle Identification Number
  10
- Outline of the Fi System
  11
- Vehicle View
  11
- FI System
  12
- Electronic Control-Related Features
  17
- Outline of the UBS
  22
  - UBS Diagram
    24
  - UBS Hydraulic Pressure Map
    25
- Outline of the ABS
  26
  - ABS Layout
    27
  - Brake Force and Vehicle Stability
    28
  - Wheel Slip and Hydraulic Control
    28
  - ABS Operation and Vehicle Control
    29
  - Electronic ABS Features
    30
  - ABS Block Diagram
    31
- ABS Component Functions
  31
  - Wheel Sensors and Wheel Sensor Rotors
    31
  - ABS Warning Light
    32
  - Hydraulic Control Valve
    33
  - Hydraulic Unit Assembly
    33
  - ABS Control Operation
    34
  - Abs Ecu
    34
  - Normal Braking (ABS Not Activated and UBS Not Activated)
    35
- UBS and ABS Operation
  35
- ABS Warning Light and Operation
  39
- ABS and UBS Function
  40
- Display
  41
- Glossary
  41
  - Speedometer
    41
  - Information Display
    42
  - Tachometer
    42
  - ERS Indicator (YZF-R1M)
    43
  - GPS Indicator
    43
  - YRC Items LCS/QS/LIF
    43
  - Error Mode
    44
- Menu Screen
  45
  - Pwr
    46
  - Lcs
    47
  - Lif
    47
  - Qss
    47
  - Ers (Yzf-R1M)
    48
  - “Lap Time”
    49
  - “Logging” (for CCU-Equipped Models)
    50
  - “Maintenance”
    50
  - “Unit”
    50
  - “Shift IND Brightness”
    52
  - “Shift Indicator”
    52
  - “Tach IND Setting”
    53
  - “Display Setting”
    54
  - “Peak Rev IND Setting”
    54
  - “All Reset”
    56
  - “Clock”
    56
  - Aluminium Bolts
    57
- Gaskets, Oil Seals and O-Rings
  57
- Important Information
  57
- Preparation for Removal and Disassembly
  57
- Replacement Parts
  57
- Bearings and Oil Seals
  58
- Circlips
  58
- Lock Washers/Plates and Cotter Pins
  58
- Rubber Parts
  58
- Basic Service Information
  59
- Quick Fasteners
  59
- Electrical Parts Handling
  60
- Electrical System
  60
  - Checking the Connections
    62
  - Checking the Electrical System
    62
- Special Tools
  65
Specifications
75
- General Specifications
  76
- Engine Specifications
  77
- Chassis Specifications
  82
- Electrical Specifications
  86
- Tightening Torques
  89
- General Tightening Torque Specifications
  89
- Engine Tightening Torques
  90
- Chassis Tightening Torques
  97
- Lubrication Points and Lubricant Types
  102
- Engine
  102
- Chassis
  103
- Lubrication System Chart and Diagrams
  106
- Engine Oil Lubrication Chart
  106
- Lubrication Diagrams
  108
- Cooling System Diagrams
  122
- Cable Routing
  126
Periodic Checks and Adjustments
173
- General Maintenance and Lubrication Chart
  175
- Introduction
  175
- Periodic Maintenance Chart for the Emission Control System
  175
- CHECKING the FUEL LINE (Primary Injector)
  178
- CHECKING the FUEL LINE (Secondary Injector)
  178
- Checking the Spark Plugs
  178
- Adjusting the Valve Clearance
  179
- Checking the Engine Idling Speed
  183
- Checking the Throttle Body Synchronization
  183
- Synchronizing the Throttle Bodies
  183
- Adjusting the Throttle Body Synchronization
  184
- Checking the Crankcase Breather Hose
  185
- Checking the Exhaust System
  185
- Checking the Throttle Body Joints
  185
- Adjusting the Exhaust Gas Volume
  186
- Checking the Air Induction System
  186
- Replacing the Air Filter Element
  186
- Adjusting the Clutch Lever Free Play
  187
- Adjusting the Front Disc Brake
  188
- Checking the Brake Fluid Level
  188
- Checking the Brake Operation
  188
- Adjusting the Rear Disc Brake
  189
- Checking the Front Brake Pads
  189
- Checking the Rear Brake Pads
  189
- Bleeding the Hydraulic Brake System (ABS)
  190
- Checking the Front Brake Hoses
  190
- Checking the Rear Brake Hose
  190
- Checking the Tires
  191
- Checking the Wheels
  191
- Adjusting the Drive Chain Slack
  193
- Checking the Swingaram Operation
  193
- Checking the Wheel Bearings
  193
- Lubricating the Swingarm Pivot
  193
- Lubricating the Drive Chain
  194
- Checking and Adjusting the Steering Head
  195
- Checking the Chassis Fasteners
  196
- Checking the Front Fork
  196
- Checking the Sidestand Switch
  196
- Checking the Steering Damper
  196
- Lubricating the Brake Lever
  196
- Lubricating the Clutch Lever
  196
- Lubricating the Pedal
  196
- Lubricating the Sidestand
  196
- Lubricating the Steering Head
  196
- ADJUSTING the FRONT FORK LEGS (for YZF-R1)
  197
- ADJUSTING the PRELOAD of the FRONT FORK LEGS (for YZF-R1M)
  198
- Compression Damping
  198
- Adjusting the Damping Force of the Rear Shock Absorber
  199
- Adjusting the Damping Force of the Front Fork Legs
  199
- Adjusting the Rear Shock Absorber Assembly
  200
- Rebound Damping
  201
- Adjusting the Preload of the Rear Shock Absorber Assembly
  202
- Checking the Engine Oil Level
  203
- Changing the Engine Oil
  204
- Measuring the Engine Oil Pressure
  205
- Checking the Coolant Level
  206
- Checking the Cooling System
  206
- Changing the Coolant
  207
Cooling System
208
- Adjusting the EXUP Cables
  209
- Adjusting the Rear Brake Light Switch
  210
- Checking and Lubricating the Cables
  210
- Checking the Throttle Grip
  210
- Adjusting the Headlight Beams
  212
- Chassis
  215
- Disassembling the Mudguard Assembly
  220
- Removing the Electrical Components Tray
  229
- Installing the Front Side Cowlings
  230
- REMOVING the FRONT SIDE COWLINGS (for YZF-R1)
  230
- REMOVING the FRONT SIDE COWLINGS (for YZF-R1M)
  230
- INSTALLING the FRONT SIDE COWLINGS (for YZF-R1)
  231
- INSTALLING the FRONT SIDE COWLINGS (for YZF-R1M)
  231
- Removing the Front Panels
  231
- INSTALLING the SIDE COVER (Left)
  232
- REMOVING the SIDE COVER (Left)
  232
- Installing the ECU (Engine Control Unit)
  233
- Removing the ECU (Engine Control Unit)
  233
- General Chassis (3)
  234
- Installing the Windshield Assembly
  238
- Removing the Windshield Assembly
  238
- Checking the Air Intake Duct Valve
  239
- Checking the Vacuum Line
  239
- Installing the Air Intake Duct Valve
  240
- Front Wheel
  241
  - Removing the Front Wheel and Brake Discs
    242
  - Disassembling the Front Wheel
    243
- Checking the Front Wheel
  244
- Disassembling the Front Wheel
  244
- Removing the Front Wheel
  244
- Assembling the Front Wheel
  245
- Maintenance of the Front Wheel Sensor and Sensor Rotor
  246
- Adjusting the Front Wheel Static Balance
  247
- Installing the Front Wheel (Disc Brake)
  248
- Removing the Rear Wheel
  254
- Checking and Replacing the Rear Wheel Sprocket
  255
- Checking the Rear Wheel Drive Hub
  255
- Disassembling the Rear Wheel
  255
- Assembling the Rear Wheel
  256
- Adjusting the Rear Wheel Static Balance
  257
- Installing the Rear Wheel (Disc Brake)
  257
- Maintenance of the Rear Wheel Sensor and Sensor Rotor
  257
- Front Brake
  260
- Checking the Front Brake Discs
  265
- Introduction
  265
- Replacing the Front Brake Pads
  266
- Removing the Front Brake Calipers
  267
- Assembling the Front Brake Calipers
  268
- Checking the Front Brake Calipers
  268
- Installing the Front Brake Calipers
  269
- Assembling the Front Brake Master Cylinder
  270
- Checking the Front Brake Master Cylinder
  270
- Installing the Front Brake Master Cylinder
  270
- Rear Brake
  272
- Checking the Rear Brake Disc
  276
- Introduction
  276
- Replacing the Rear Brake Disc
  276
- Removing the Rear Brake Caliper
  277
- Checking the Rear Brake Caliper
  278
- Assembling the Rear Brake Caliper
  279
- Installing the Rear Brake Caliper
  279
- Checking the Rear Brake Master Cylinder
  280
- The Rear Brake Master Cylinder Installation
  281
- ABS (Anti-Lock Brake System)
  282
- Removing the Hydraulic Unit Assembly
  282
- ABS Components Chart
  284
- Removing the Hydraulic Unit Assembly
  285
- Checking the Brake Pipes
  286
- Checking the Hydraulic Unit Assembly
  286
- Installing the Hydraulic Unit Assembly
  286
- Hydraulic Unit Operation Test
  287
- ABS Reaction-Force Confirmation
  289
- Checking the ABS Warning Light
  290
- Handlebars
  291
- Removing the Handlebars
  292
- Checking the Handlebars
  293
- Installing the Handlebars
  293
- FRONT FORK (for YZF-R1)
  296
  - Removing the Front Fork Legs
    296
  - Disassembling the Front Fork Legs
    297
- DISASSEMBLING the FRONT FORK LEGS (for YZF-R1)
  298
- REMOVING the FRONT FORK LEGS (for YZF-R1)
  298
- ASSEMBLING the FRONT FORK LEGS (for YZF-R1)
  300
- CHECKING the FRONT FORK LEGS (for YZF-R1)
  300
- INSTALLING the FRONT FORK LEGS (for YZF-R1)
  304
- FRONT FORK (for YZF-R1M)
  307
- DISASSEMBLING the FRONT FORK LEGS (for YZF-R1M)
  309
- REMOVING 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
- Removing the Lower Bracket
  317
- Steering Head
  317
- Checking the Steering Head
  319
- Removing the Lower Bracket
  319
- Checking the Steering Damper
  320
- Installing the Steering Head
  320
- Rear Shock Absorber Assembly Removal
  321
- Disposing of a Rear Shock Absorber
  325
- Removing the Rear Shock Absorber Assembly
  325
- Checking the Connecting Arm and Relay Arm
  326
- Checking the Rear Shock Absorber Assembly
  326
- Disassembling the Rear Shock Absorber Assembly
  326
- Assembling the Rear Shock Absorber Assembly
  327
- Installing the Relay Arm
  327
- Installing the Rear Shock Absorber Assembly
  328
  - Removing the Swingarm
    329
  - Checking the Swingram
    330
- Removing the Swingarm
  330
  - Installing the Swingram
    331
  - Removing the Drive Chain
    333
- Checking the Drive Chain
  334
- Checking the Rear Wheel Drive Hub
  335
- Checking the Rear Wheel Sprocket
  335
- Installing the Drive Chain
  336
- Adjusting the Shift Pedal
  337
- Engine
  339
- Engine Inspection
  342
Measure the Compression Pressure
342
- Engine Removal
  344
  - Removing the Muffler and Exhaust Pipe
    344
  - Disconnecting the Leads and Hoses
    346
- Installing the Engine
  348
- Removing the Engine
  348
- Installing the Exhaust Pipe and Muffler
  349
- Camshafts
  350
- Removing the Camshafts
  354
- Checking the Camshafts
  355
- Removing the Rocker Arms and Rocker Arm Shafts
  355
- Checking the Rocker Arms and Rocker Arm Shafts
  357
- Checking the Timing Chain and Camshaft Sprocket
  357
- Checking the Timing Chain Guides
  358
- Checking the Timing Chain Tensioner
  358
- Assembling the Timing Chain Cover
  359
- Installing the Rocker Arms and Rocker Arm Shafts
  359
- Installing the Timing Chain Cover
  359
- Installing the Camshafts
  360
- Removing the Cylinder Head
  364
- Installing the Cylinder Head
  365
- Removing the Valves and Valve Springs
  367
- Checking the Valves and Valve Guides
  369
- Removing the Valves
  369
- Valves and Valve Springs
  369
- Checking the Valve Seats
  371
- Checking the Valve Spring Seat
  373
- Installing the Valves
  374
- Generator
  376
- Removing the Stator Coil and Generator Rotor
  376
- Installing the Generator
  377
- Removing the Generator
  377
- Removing the Starter Clutch
  379
- Checking the Starter Clutch
  380
- Installing the Starter Clutch
  380
- Electric Starter
  382
  - Removing the Starter Motor
    382
  - Disassembling the Starter Motor
    383
- Checking the Starter Motor
  384
- Assembling the Starter Motor
  385
  - Removing the Oil Pan and Oil Pump
    386
  - Disassembling the Oil Pump
    388
- Checking the Sprocket and Chain
  389
- Removing the Oil Pan
  389
- Checking the Oil Pump
  390
- Checking the Relief Valve
  390
- Assembling the Oil Pump
  391
- Checking the Oil Delivery Pipes
  391
- Checking the Oil Strainer
  391
- Installing the Oil Pump
  391
- Installing the Oil Pan
  393
- Clutch
  394
  - Removing the Clutch Cover
    394
  - Removing the Pull Lever Shaft
    395
  - Removing the Clutch
    396
- Removing the Clutch
  397
- Checking the Clutch Plates
  398
- Checking the Friction Plates
  398
- Checking the Clutch Boss
  399
- Checking the Clutch Housing
  399
- Checking the Clutch Springs
  399
- Checking the Pressure Plate
  399
- Checking the Primary Drive Gear
  400
- Checking the Primary Driven Gear
  400
- Checking the Pull Lever Shaft and Pull Rod
  400
- Installing the Clutch
  400
- Removing the Shift Shaft and Stopper Lever
  403
- Shift Shaft
  403
- Checking the Shift Shaft
  404
- Checking the Stopper Lever
  404
- Installing the Shift Shaft
  404
- Crankcase
  405
  - Removing the Crankcase Breather Cover and Switches
    405
  - Separating the Crankcase
    407
- Assembling the Crankcase
  408
- Checking the Crankcase
  408
- Disassembling the Crankcase
  408
- Installing the Crankcase Breather Cover
  410
- Installing the Oil Pressure Switch
  410
- Installing the Gear Position Sensor
  411
- Removing the Connecting Rods and Pistons
  412
- Connecting Rods and Pistons
  413
- Removing the Connecting Rods and Pistons
  413
- Checking the Cylinder and Piston
  414
- Checking the Piston Rings
  415
- Checking the Piston Pin
  416
- Checking the Connecting Rods
  417
  - Installing the Connection Rod and Piston
    419
  - Removing the Crankshaft and Balancer Shaft
    425
- Checking the Crankshaft
  426
- Checking the Oil Nozzles
  426
- Crankshaft and Balancer Shaft
  426
- Removing the Crankshaft and Balancer Shaft
  426
- Checking the Balancer Shaft
  428
- Installing the Crankshaft
  429
- Installing the Balancer Assembly
  430
- Removing the Transmission, Shift Drum Assembly, and Shift Forks
  431
- Transmission
  431
- Disassembling the Main Axle Assembly
  432
- Checking the Shift Forks
  435
- Removing the Transmission
  435
- Assembling the Main Axle and Drive Axle
  436
- Checking the Shift Drum Assembly
  436
- Checking the Transmission
  436
- Installing the Transmission
  437
  - Cooling System
    439
  - Removing the Radiator
    440
- Checking the Radiator
  441
- Installing the Radiator
  442
- Removing the Oil Cooler
  443
- Checking the Oil Cooler
  444
- Installing the Oil Cooler
  444
- Removing the Thermostat
  445
- Assembling the Thermostat Assembly
  446
- Checking the Thermostat
  446
- Installing the Thermostat Assembly
  446
- Removing the Thermostat Assembly
  446
  - Removing the Water Pump
    448
  - Disassembling the Water Pump
    449
- Assembling the Water Pump
  450
- Checking the Water Pump
  450
- Installing the Water Pump
  451
Fuel System
453
Electrical System
479
Troubleshooting
679
- Self-Diagnostic Function and Diagnostic Code Table (ECU)
  684
- Communication Error with the Meter
  685
- Diagnostic Code: Sensor Operation Table
  686
- Diagnostic Code: Actuator Operation Table
  689
- Event Code Table
  692
- Wiring Diagram Items
  695
- Wiring Diagram
  701

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