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YZF-R1(V) YZF

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2. 12 CABLE ROUTING SPEC L 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 M Feed a lead wire through the U shape cutout of the console panel 13 1 Right handlebar switch lead 2 Clutch cable 3 Main switch lead 4 Left handlebar switch lead 5 Horn lead 6 Horn 7 Throttle cables Brake hose 9 Throttle cable return side 0 Throttle cable pull side CABLE ROUTING SPEC Route the clutch cable so as to get along the front side of the main switch after passing it through the guide Pass the main switch lead through the guide wire C Pass the left handlebar switch lead through the guide wire D Point the tip of the band exces sive part to the le
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4. 70 4 ases ENG NOTE When adjusting the clutch assembly width by replacing the clutch plate s be sure to replace the clutch plate 1 fast After replacing the clutch plate 1 if specifica tions cannot be met replace the clutch plate 5 EAS00282 CHECKING THE CLUTCH SPRINGS YZF R1S The following procedure applies to all of the clutch springs 1 Check clutch spring Damage Replace the clutch springs as a set 2 Measure clutch spring free length Out of specification Replace the clutch springs as a set CZ Clutch spring free length 7 43 8 1 72 41 6 1 64 EAS00284 CHECKING THE CLUTCH HOUSING YZF R1S 1 Check clutch housing dogs Damage pitting wear Deburr the clutch housing dogs or replace the clutch housing NOTE Pitting on the clutch housing dogs will cause erratic clutch operation 2 Check bearing Damage wear Replace the bearing and clutch housing 719 ases ENG 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 Pitting on the clutch boss splines will cause e
5. CABLE ROUTING SPEC 27 INTRODUCTION PERIODIC MAINTENANCE AND LUBRICATION INTERVALS CHK ADJ PERIODIC CHECKS AND ADJUSTMENTS INTRODUCTION This chapter includes all information necessary to perform recommended checks and adjustments If followed these preventive maintenance procedures will ensure more reliable vehicle operation a longer service life and reduce the need for costly overhaul work This information applies to vehicles already in service as well as to new vehicles that are being prepared for sale All service technicians should be familiar with this entire chapter 500036 500037 PERIODIC MAINTENANCE AND LUBRICATION INTERVALS NOTE The annual checks must be performed every year except if a kilometer based maintenance is per formed instead From 50 000 km repeat the maintenance intervals starting from 10 000 km tems marked with an asterisk should be performed by a Yamaha dealer as they require special tools data and technical skills ODOMETER READING x 1 000 km ANNUAL 1 10 20 30 40 CHECK Check fuel hoses for cracks or damage N N N N CHECK OR MAINTENANCE JOB Fuel line Check condition 4 Clean and regap Replace N Spark plugs Check valve clearance
6. 5 CG y 1 Heat protector 2 Crankshaft position sensor lead 3 Neutral switch lead 4 Ground lead 5 Coolant reservoir tank 6 Battery positive lead 7 Starter relay 8 Turn signal relay 9 Main fuse 9 Lean angle sensor 1 Atmospheric pressure sensor 2 Tail brake light lead 3 Rear fender Seat lock cable Anti safety alarm coupler 9 Starting circuit cut off relay CABLE ROUTING SPEC 47 Battery negative lead Starter motor lead A C magneto lead 29 Oil level switch lead Sidestand switch lead 22 Throttle body lead 3 Coolant reservoir tank drain hose 4 Fuel tank drain hose 5 Cover 7 Radiator fan motor lead left Radiator fan motor lead right 8 Wire harness 09 Pipe Frame 8 Coolant reservoir tank hose 62 Thermo stat assembly breather hose 83 Throttle body side cap 34 Mud guard 5 Turn signal light lead 36 License plate light lead 6 Rear fender rib Speed sensor lead 99 Rear brake
7. CHASSIS TIGHTENING 5 LUBRICATION POINTS AND LUBRICANT TYPES PERIODIC CHECKS AND ADJUSTMENTS INTRODUCTION 4 icc cone Pha EA GG RR PERIODIC MAINTENANCE AND LUBRICATION INTERVALS CHASSIS Rate Sea PES ADJUSTING THE FRONT FORK 5 ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY CHASSIS FRONT WHEEL AND BRAKE DISCS REAR WHEEL AND BRAKE DISCS REAR BRAKE DISC AND REAR WHEEL SPROCKET FRONT SOU FRONT FORK LEGS eee teks DISASSEMBLING THE FRONT FORK LEGS CHECKING THE FRONT 1 8 ASSEMBLING THE FRONT FORK LEGS REAR SHOCK ABSORBER ASSEMBLY REMOVING THE REAR SHOCK ABSORBER ASSEMBLY INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY SWINGARM AND DRIVE REMOVING THE SWINGARM CHECKING THE SWINGARM CHECKING THE CONNECTING ROD ASSEMBLY CHECKING THE DRIVE ENGINE INSTALLING THE 5 atat m bites obtuso ates CLUTCH iade Baal
8. 2006 YZF R1 V YZF R1S V SUPPLEMENTARY SERVICE MANUAL FOREWORD This Supplementary Service Manual has been prepared to introduce new service and data for the YZF R1 V YZF R1S 2006 For complete service information procedures it is necessary to use this 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 is expressly prohibited 500002 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 Repair and maintenance work attempted by anyone without this knowledge is likely to render the vehicle unsafe and unfit for use Yamaha Motor Company Ltd is continually striving to improve all of its models Modifications and significant changes in specifications or procedures will be forwarded to all authorized Yamaha deal ers and will appear in future editions of this ma
9. ENG REMOVING THE CLUTCH YZF R1S 1 Remove clutch cover 1 gasket NOTE LL LLL 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 2 Remove compression spring bolts 1 compression springs pressure plate 2 pull rod 3 3 Remove e friction plate 1 1 PLR ENN EN 3 lt LY 4 Remove clutch plate 1 1 friction plate 2 clutch plate 2 clutch plate friction plate e clutch damper spring clutch damper spring seat 5 Straighten the clutch boss nut rib 1 67 68 2 6 Loosen clutch boss nut 1 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 pressure plate 2 conical spring washer thrust plate 2 EAS00280 CHECKING THE FRICTION PLATES YZF R1S The following procedure applies to all of the friction plates 1 Check friction plate Damage wear Replace the friction plates as a set 2 Measure e friction plate thickness Out of specification Replace the friction plates as a set NOTE Measure the friction plate at four places Friction plate thickness 2 9 3 1 mm 0 114 0 122 in Limit 2 8 mm 0 110 in LY
10. CABLE ROUTING SPEC A Clamp the leads so that they are positioned inner of the vehi cle than the washer position after routing them between the frame and radiator stay Align the clamp position with the tap ing sections of leads Point the tip of the clamp excessive part to the down front side of the vehicle What the clamp fastens at this stage are the handlebar switch main switch and immobilizer leads B Pass the main switch lead left handlebar switch lead immobilizer lead between the frame and the heat protector To the coolant reservoir tank D Fold back the clamp and secure it after passing the lead through the clamp To the EXUP servo motor CABLE ROUTING SPEC Pass the coolant reservoir tank I Route the lead by the inside P 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 hose through the clamp from J There should be no exposure of tion finally after routing other the outer side of the water pump bared conductors due to the leads and hoses in the guide inlet pipe after routi
11. Job Part Remarks Removing the clutch Compression spring Pressure plate Pull rod Bearing Friction plate 1 Clutch plate 1 Friction plate 2 Wire clip Clutch plate 2 Friction plate 3 Clutch damper spring Clutch damper spring seat 63 nn Sn N N Remove the parts in the order listed 10 Nm 1 0 7 2 ftelb Remarks Clutch boss nut Washer Thrust plate 1 Clutch boss Thrust plate 2 Clutch housing Bearing For installation reverse the removal procedure 64 YZF R1S 10 Nm 1 0 7 2 ftelb Job Part Remarks Removing the clutch Compression spring Pressure plate 1 Pull rod Bearing Friction plate 1 Clutch plate 1 Friction plate 2 Clutch plate 2 Clutch plate 3 Friction plate 3 Clutch damper spring Clutch damper spring seat Clutch boss nut 65 lt S Remove the parts in the order listed YZF R1S 10 Nm 1 0 7 2 ftelb Job Part REMAKE Spring Clutch boss Pressure plate 2 Conical spring washer Thrust plate 2 Clutch housing Bearing For installation reverse the removal procedure 66
12. ENGINE Lubrication point Lubricant Valve lifter surfaces intake and exhaust Valve stem ends intake and exhaust 4 1 CHASSIS Lubrication point Lubricant Pivot shaft CDA 10 LUBRICATION DIAGRAMS LUBRICATION DIAGRAMS 9 Main axle Oil delivery pipe 3 Drive axle EAS00035 CABLE ROUTING 1 Ground lead 2 Meter lead 3 Stay 1 4 Auxiliary light lead right 5 Headlight lead 6 Auxiliary light lead left 7 Console panel 1 Duct 1 9 Console panel 2 19 Duct 2 1 Headlight lead right 42 Headlight lead left CABLE ROUTING SPEC A Insert to the rib of the head F after passing over the light Either location of the right upper side of the duct and left relays is acceptable G Clamp the head light lead by B The lead should not stretch too wrapping and insert it to the much intake air grill hole only at the Direction of the ground terminal right side can be either top side or flip not connect the wire to the side coupler with the plug for Make sure to insert the coupler options and boot to the stay 1 hole 1 To the turn signal light D The speedometer lead should J To the wire harness Cut the tip of the clamp Clamp the headlight lead to the positioning white tape section not be strained To the stay 1 hole
13. iy 69 719 Due CHECKING THE CLUTCH PLATES YZF R1S The following procedure applies to all of the clutch plates 1 Check e clutch plate Damage Replace the clutch plates as a set 2 Measure clutch plate warpage with a surface plate and thickness gauge D Out of specification Replace the clutch plates as a set Clutch plate warpage limit 0 1 mm 0 0039 in 3 Measure assembly width of the friction plates and clutch plates Out of specification Adjust Assembly width 42 4 43 0 mm 1 67 1 69 in NOTE Perform the thickness measurement without applying the oil Assembly width adjusted by clutch plate 1 and 2 b Select the clutch plate from the following table Clutch plate 1 Part No Thickness 1 6 mm 0 062 in 2 0 mm 0 079 in 2 3 mm 0 091 in 4B1 16324 00 5VY 16325 00 STD 4B1 16325 00 Clutch plate 2 Part No 5VY 16325 00 Thickness 2 0 mm 0 079 in 2 3 mm 0 091 in 4B1 16325 00
14. 26 Nm 2 6 19 ftelb Job Part Remarks Removing the front wheel and brake Remove the parts in the order listed discs NOTE Place the vehicle on a suitable stand so that the front wheel is elevated Brake hose holder left and right Front brake caliper left and right Front wheel axle pinch bolt Front wheel axle bolt Front wheel axle Collar left and right Front wheel Front brake disc left and right For installation reverse the removal procedure 36 REAR WHEEL AND BRAKE Discs CHAS 500560 REAR WHEEL AND BRAKE DISCS REAR BRAKE DISC AND REAR WHEEL SPROCKET YZE R1S 30 8 0 22 fiib Job Part Remarks Removing the rear brake disc and Remove the parts in the order listed rear wheel sprocket Rear brake disc Rear wheel sprocket Collar Oil seal Bearing Rear wheel drive hub Rear wheel drive hub damper Rear wheel ANoaKWND a WO For installation reverse the disassembly procedure 37 REAR WHEEL AND BRAKE Discs CHAS Job Part Remarks Disassembling the rear wheel Disassemble the parts in the order listed Collar Bearing Spacer Oil seal Bearing For assembly reverse the disassembly procedure 38 EAS00648 FRONT FORK FRONT FORK LEGS YZF R1S 20 Nm 2 0 mekg 14 ftelb 25 Nm 2 5 mekg 18 ftelb 1111111
15. s GLUTCH COVER er dopo oe CLUTCH oe hase Rc Rcs Ax ea data REMOVING THE CLUTCH es ETE CHECKING THE FRICTION CHECKING THE CLUTCH CHECKING THE CLUTCH 5 CHECKING THE CLUTCH HOUSING CHECKING THE PRESSUR 2 CHECKING THE CLUTCH 55 CHECKING THE PRESSURE PLATE 1 CHECKING THE PULL LEVER SHAFT AND PULL ROD INSTALLING THE CLUTCH 22 YZF R1 V YZF R1S 2006 WIRING DIAGRAM GENERAL INFORMATION EAS00027 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 When placing an order refer to the list provided below to avoid any mistakes NOTE For U S A and Canada use part number starting with Y M YU or ACC For others use part number starting with 90890 YZF R1S Tool No Tool name Function Illustration Front fork cap bolt wrench 90890 01472 This tool is used to loosen or tighten the front fork cap bolt Damper
16. 3 Check damper rod 1 Damage wear Replace Obstruction Blow out all of the oil pas sages with compressed air damper rod adjusting rod Bends damage gt Replace CAUTION front fork leg has a built in damper adjusting rod and a very sophisticated internal construction which are particu larly sensitive to foreign material When disassembling and assembling the front fork leg do not allow any foreign material to enter the front fork 4 Check cap bolt 1 Damage Replace cap bolt O ring 44 FRONT FORK CHAS 500659 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 NOTE LL LLL When assembling the front fork leg be sure to replace the following parts oil seal clip oil seal dust seal Before assembling the front fork leg make sure all of the components are clean 1 Install inner tube 1 damper rod assembly 2 2 Tighten damper rod assembly 48 Nm 4 8 35 6 LOCTITE While holding the inner tube with the damper rod holder tighten the damper rod assem bly 7725 Damper rod holder 7 90890 01504 3 Lubricate inner tube s outer surface Recommended lubr
17. Adjust Replace Check operation Adjust i Check operation fluid level and vehicle for fluid leakage N N y Whenever worn to the limit Valves Every 40 000 km Air filter element Clutch Front brake e Replace brake pads Check operation fluid level and vehicle for fluid leakage N N Whenever worn the limit Rear brake Replace brake pads Check for cracks or damage N N Every 4 years Brake hoses Replace Check runout and for damage N N Check tread depth and for damage Replace if necessary Check air pressure Correct if necessary Check bearing for looseness or damage N Check operation and for excessive play N y e Lubricate with lithium soap based grease Every 50 000 km e Check chain slack alignment and condition e Adjust and lubricate chain with a special O ring chain lubri cant thoroughly e Check bearing play and steering for roughness N N Lubricate with lithium soap based grease Every 20 000 km Check operation and for oil leakage N Make sure that all nuts bolts and screws properly tight 4 ened Wheels Tires Wheel bearings Swingarm Every 800 km and after washing the vehicle or Drive chain riding in the rain Steering bearings Steering damper Chassis fasteners Check operation Sidestand Lubricate S
18. NOTE While filling the front fork leg keep it upright After filling slowly pump the front fork leg up and down to distribute the fork oil 46 47 FRONT FORK CHAS 10 Install spring seat 1 spring guide 2 spacer 3 clip 4 fork spring 5 spring seat upper nut 7 damper adjusting rod cap bolt 9 fork bracket fork stay Install the spring seat spring guide spacer and circlip b Install the fork spring spring seat upper and nut c Press down on the spring seat with the fork spring compressor 1 d Pull up the rod puller and install the nut gt Fork spring compressor 90890 01441 01441 Remove the rod puller and adapter f Install the nut 1 and position it as specified Distance 6 More than 25 mm 0 98 in g Install the damper adjusting rod and cap bolt and then finger tighten the cap bolt until it stop NOT E Install the cap bolt with rebound damping screw fully loosened h Hold the cap bolt and tighten the nut to specification Y Nut 25Nm 2 5 18 i Remove the fork spring compressor WARNING fork spring is compressed Always use a new cap bolt O ring REAR SHOCK ABSORBER ASSEMBLY CHAS EAS00685 REAR SHOCK ABSOR
19. bottom cowling rear cowling upper Refer to COWLINGS in chapter protector muffler catalyst pipe assembly EXUP servo motor Refer to EXHAUST PIPE in chapter 5 3 Remove connecting rod front bolt 1 rear shock absorber assembly lower bolt 2 relay arm to swingarm bolt 3 NOTE n While removing the rear shock absorber assembly lower bolt hold the swingarm so that it does not drop down 4 Remove e rear shock absorber assembly upper 1 rear shock absorber assembly NOTE Raise the swingarm and then remove the rear shock absorber assembly from between the swingarm 2 REAR SHOCK ABSORBER ASSEMBLY CHAS 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 rear shock absorber assembly NOTE When installing the rear shock absorber assembly lift up the swingarm Install the connecting rod front bolt from the left 4 Tighten rear shock absorber assembly upper nut 92 Nm 9 2 mekg 67 ftelb rear shock absorber assembly lower nut 44 Nm 4 4 mekg 32 ftelb relay arm to swingarm nut 44 Nm 4 4 mekg 32 ftelb connecting rod front nut 44 Nm 4 4 mekg 32 ftelb 5 Install EXUP servo motor catalyst pipe a
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21. 5 Straighten the clutch boss nut rib D For installation reverse the removal procedure EAS00008 SYMBOLS The following symbols are not relevant to every vehicle Symbols 1 to 9 indicate the subject of each chapter D General information Specifications 3 Periodic checks and adjustments Chassis 5 Engine Cooling system 7 Fuel injection system Electrical system 9 Troubleshooting Symbols 9 to indicate the following 9 Serviceable with engine mounted Filling fluid 42 Lubricant 3 Special tool 49 Tightening torque 5 Wear limit clearance Engine speed 47 Electrical data Symbols 49 to 3 in the exploded diagrams indicate the types of lubricants and lubrication points Engine oil 49 Gear 29 Molybdenum disulfide oil Wheel bearing grease 62 Lithium soap based grease 23 Molybdenum disulfide grease Symbols 4 to 25 in the exploded diagrams indicate the following 64 Apply locking agent LOCTITE 25 Replace the part with a new one CONTENTS GENERAL INFORMATION SPECIAL TOOLS 252 NU SPECIFICATIONS GENERAL SPECIFICATIONS ENGINE SPECIFICATIONS CHASSIS ELECTRICAL SPECIFICATIONS TIGHTENING TORQUES ENGINE TIGHTENING 5
22. c Loosen the nut d Remove the cap bolt e Remove the spanner and fork spring com pressor WARNING The fork spring is compressed MAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 2 Remove e nut spring seat upper fork spring clip 1 spacer spring guide 3 Drain fork oil NOTE LLL Stroke the damper rod 1 several times while draining the fork oil 42 FRONT FORK CHAS 4 Remove dust seal oil seal clip 1 oil seal washer with a flat head screwdriver CAUTION Do not scratch the inner tube 5 Remove spring seat 1 NOTE Use a wire the like and bend the end 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 6 Remove damper rod assembly NOTE WE While holding the inner tube with the damper rod holder 1 loosen the damper rod assem bly Damper rod holder 90890 01504 12311703 FRONT FORK CHAS 500656 CHECKING THE FRONT FORK LEGS YZF R1S The following procedure applies to both of the front fork legs 1 Check inner tube 1 outer tube 2 Bends damage scratches Replace A WARNING Do not attempt to straighten a bent inner tube as this may dangerously weaken it 2 Measure spring free length a Out of specification Replace Spring free length 260 mm 10 24 in lt Limit gt 254 8 mm 10 03 in
23. front engine mounting bolt 1 45 Nm 4 5 33 60 EAS00196 CAMSHAFTS SN aene EN 10 Nm 1 0 7 2 ftelb Job Part 10 Nm 1 0 mekg 7 2 ftelb Remarks Removing the camshafts Pickup rotor cover Camshaft sprocket bolt Timing chain tensioner Intake camshaft cap Dowel pin Exhaust camshaft cap Dowel pin Intake camshaft Exhaust camshaft Camshaft sprocket Timing chain tensioner gasket 61 Remove the parts in the order listed Refer to CRANKSHAFT POSITION SENSOR AND PICKUP ROTOR Loosen NOTE eee During removal the dowel pins may still be connected to the camshaft caps Refer to REMOVING THE CAMSHAFTS For installation reverse the removal procedure cure CLUTCH CLUTCH COVER 12 Nm 1 2 mekg 8 7 ftelb 10 Nm 1 0 7 2 ftelb Job Part Q ty Remarks Removing the clutch cover Remove the parts in the order listed Right side cowling Namie SIE Refer to COWLINGS in chapter Right frame side panel Bottom cowling Engine oil Drain Refer to CHANGING THE ENGINE OIL in chapter 3 Cover Clutch cable Disconnect Clutch cover Clutch cover gasket Dowel pin Oil filler cap For installation reverse the removal procedure 62 10 Nm 1 0 7 2 ftelb
24. light switch lead 40 Rear frame Swingarm bracket Main fuse lead 43 Starting circuit cut off relay lead 44 signal light relay lead 45 Starter relay lead 21 positive lead Right handlebar switch lead CABLE ROUTING SPEC 40 Main fuse lead To the battery Pass the wire harness through the clamp inserted to the radia tor stay To the headlight lead C Clamp the lead between three protrusions of the pipe the first and second parts from the vehi cle front Point the tip of the clamp excessive part to the inside of the vehicle D To the vehicle right side diagram To the engine Clamp the lead between three protrusions of the pipe the inside and outside of the vehi cle G Point the tip of the clamp excessive part to the inside of the vehicle H All hoses and leads should be routed over the vehicle s upper side above the heat protector 1 To the starter motor Fasten the wire harness clank shaft position sensor lead rear brake light switch lead and speed sensor lead with a clamp Then point the tip of the clamp cut the tip of the clamp leaving 2 to 4 mm 0 08 to 0 16 in to the inside of the vehi
25. rod holder 90890 01504 This tool is used to loosening or tightening the damper rod assembly Rod puller Rod puller Rod puller attachment These tools are used to pull up the front fork damper rod GENERAL SPECIFICATIONS SPECIFICATIONS GENERAL SPECIFICATIONS Standard 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 Wheelbase 1 415 mm 55 7 in Weight Wet with oil and a full fuel tank 194 kg 428 Ib 195 kg 430 Ib Maximum load except vehicle 201 kg 443 Ib 200 kg 441 Ib YZF R1 YZF R1S YZF R1 YZF R1S ENGINE SPECIFICATIONS SPEC ENGINE SPECIFICATIONS Item Standard Limit Engine oil Recommended oil Temp a SAE10W30SE SAE10W40SE or SAE15W40SE SAE20W40SE 10 40 SAE20W50SE C SAETSWAO 7 API service SE SF SG type higher 204 40 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 Volume 12 3 12 9 0 75 0 79 0 10 0 0039 Piston Diameter D 76 975 76 990 3 0305 3 0311 Height H 12 mm 0 47 in ENGINE SPECIFICATIONS SPEC Sta
26. softer Adjusting positions Minimum 17 clicks in direction Standard 12 clicks in direction b Maximum 1 clicks in direction b with the adjusting screw fully turned in direction 32 CHK ADJUSTING THE FRONT FORK LEGS ADJ Compression damping CAUTION Never go beyond the maximum or minimum adjustment positions 1 Adjust compression damping a Turn the adjusting screw 1 in direction or b Compression damping is Direction increased suspension is harder Compression damping is Direction 0 decreased suspension is softer Adjusting positions Minimum 20 clicks in direction Standard 12 clicks in direction b Maximum 1 clicks in direction b with the adjusting screw fully turned in direction CHK ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY we 1 0 5 0 No RIS 2 T 33 EAS00158 ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY YZF R1S A 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 Adjust spring preload VVVVVVVVVVVVVVVVVVVV
27. stay YZF R1S M5 0 6 4 3 Front fork and bracket YZF R1S M5 0 6 43 Rear brake master cylinder and foot rest bracket M6 1 3 9 4 Front brake disc and front wheel YZF R1S M6 2 3 17 Front wheel axle pinch bolt YZF R1S M8 2 6 19 Cap bolt YZF R1S 2 0 14 Cap bolt and lock nut YZF R1S 2 5 18 Damper rod assembly YZF R1S 48 35 NOTE o 1 Insert the front wheel axle from the right side and tighten it with the flange bolt from the left side to 91 Nm 9 1 mekg 65 8 ftelb 2 In the order from the pinch bolt gt pinch bolt 4 pinch bolt 2 tighten each bolt to 26 Nm 2 6 mekg 19 16 without perform ing temporary tightening 3 Check that the end face of the axle head and the end face of the fork side are flush mounted If they are out of alignment make sure to fit them by adding the external force by hand or with a plastic hammer etc If the end face of the axle is not parallel to the end face of the fork align them so that one point of the axle circumference is posi tioned on the end face of the fork At this stage it can be accepted if the end face of the axle becomes partially concave to the end face of the fork 4 In the order from the pinch bolt 4 pinch bolt 3 gt pinch bolt 2 tighten each bolt to 26 Nm 2 6 mekg 19 10 without perform ing temporary tightening LUBRICATION POINTS AND LUBRICANT TYPES SPEC LUBRICATION POINTS AND LUBRICANT TYPES
28. to 4 mm 0 08 to 0 16 in to the inside of the vehicle EE To the air filter FF the throttle body GG To install the cover 7 install so as to set each coupler in the cover Make sure that each lead is not caught by the cover 7 24 CABLE ROUTING SPEC HH insert the wire harness wrap MM Do not place it beyond pipe 3 PP Route the leads in random ping clamp to the hole of the in the direction to the external order frame part of the vehicle sure that the lead is fas NN Route each lead higher than tened with the guide of the the frame plate pass it to the radiator stay inside of the vehicle from the JJ the right handlebar switch hole Leads should be routed KK Battery negative lead should in random order not run on the swingarm Clamp can be inserted in any bracket direction LL The hoses should not be OO Route each lead lower than located higher than the throt the frame plate Leads should tle body side cap over the up be routed in random order side of the vehicle Clamp can be inserted in any direction 25 1 Fuel tank 2 O ri
29. with the groove in the axle 7725 Universal clutch holder 7 90890 04086 91042 4 Install clutch damper spring seat 1 clutch damper spring 2 NOTE Install the clutch damper spring as shown in the illustration 5 Lubricate e friction plates clutch plates with the recommended lubricant Recommended lubricant Engine oil 74 ENG 6 Install friction plate friction plate 2 clutch plate e clutch plate 2 clutch plate 1 1 NOTE _ Assemble the friction plates and clutch plates according to the installation order 7 Install e friction plate 1 1 NOTE Install the last friction plate shifting half phase 8 Install bearing pull rod pressure plate 1 1 NOTE Align the punch mark b on the pressure plate with the punch mark on the clutch boss 9 Install clutch springs clutch spring bolts 1 1 Y 71 Tighten the clutch spring bolts in stages a crisscross pattern 75 cure ENG 10 Install pull lever NOTE n Install the pull lever with the mark facing toward upper side 11 Install e clutch cover clutch cover gasket Install the pull rod so that the teeth face towards the rear of the vehicle Then install the clutch cover Apply oil onto the bearing Apply molybdenum disulfide grease onto th
30. 11111 Job Part FRONT FORK CHAS 6 Nm 0 6 4 3 ftelb 48 Nm 4 8 35 ftelb Remarks 9 6 66 6 990 Disassembling the front fork legs Fork stay Fork bracket Cap bolt O ring Damper adjusting rod Nut Spring seat upper Fork spring Clip Spacer Disassemble the parts in the order listed NOTE The following the procedure applies to both of the front fork legs lI l l l l l c 39 FRONT FORK CHAS YZF R1S 20 Nm 2 0 mekg 14 ftelb 25 Nm 2 5 mekg 18 ftelb 111111111111 6 Nm 0 6 4 3 ftelb 48 Nm 4 8 35 ftelb Job Part Remarks Spring guide Spring seat Dust seal Oil seal clip Oil seal Washer Damper rod assembly Inner tube Outer tube 9 09090600 For assembly reverse the disassembly procedure 40 41 FRONT FORK CHAS 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 1 from the damper adjusting rod Press down on the spacer with the fork spring compressor 4 b Install the spanner 5 between the nut 3 and the spring seat upper 2 Fork spring compressor 90890 01441 YM 01441
31. 2510201 properly routed away from the drive chain and below the swingarm 5 Lubricate drive chain Recommended lubricant Engine oil or chain lubricant suitable for O ring chains 6 Check drive sprocket rear wheel sprocket More than 1 4 tooth 8 wear Replace the drive chain sprockets as a set Bent teeth Replace the drive chain sprockets as a set Correct Drive chain roller 9 Drive chain sprocket 12560103 56 aene EN 51 5 1 37 ftelb Pw 45 Nm 4 5 m kg 33 ftelb w 51 Nm 5 1 mekg 37 ftelb 45 Nm 4 5 mekg 33 ftelb 7 Nm 0 7 5 1 ftelb Job Part Remarks Removing the engine Remove the parts in the order listed NOTE Place a suitable stand under the frame and engine Right front engine mounting bolt Engine mount collar inside YZF R1 Engine mount collar inside outside YZF R1S Engine mount collar outside YZF R1 Engine mount collar center YZF R1S Left front engine mounting bolt Lower self locking nut Lower engine mounting bolt Upper self locking nut 57 w 51 5 1 37 ftelb w 51 Nm 5 1 mekg 37 ftelb 45 4 5 mekg 33 7 Nm 0 7 5 1 ftelb Remarks Upper engine mounting bolt Engine mounting adjust bolt NOTE Engine Use the pivot shaft wrench and adapter t
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33. BER ASSEMBLY YZF R1S Ry 92 Nm 9 2 67 ftelb Job Part 44 Nm 4 4 32 ftelb Remarks Removing the rear shock absorber assembly Rider seat and passenger seat Fuel tank Bottom cowling and rear cowling upper Protector muffler catalyst pipe assembly and EXUP servo motor Self locking nut bolt Self locking nut bolt Self locking nut bolt Self locking nut Rear shock absorber assembly Oil seal bearing collar Collar self locking nut bolt Connecting rod Oil seal bearing collar Remove the parts in the order listed Refer to SEATS in chapter 3 Refer to FUEL TANK in chapter Refer to COWLINGS in chapter Refer to EXHAUST PIPE in chapter 5 REAR SHOCK ABSORBER ASSEMBLY CHAS YZF R1S 44 Nm 4 4 32 ftelb ER 92 Nm 9 2 mekg 67 ftelb Job Part Remarks Relay arm For installation reverse the removal procedure 49 50 REAR SHOCK ABSORBER ASSEMBLY CHAS EAS00690 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY YZF R1S 1 Stand the vehicle on a level surface A WARNING Becurely support the vehicle so that there is no danger of it falling over NOTE Place the vehicle on a suitable stand so that the rear wheel is elevated 2 Remove rider seat and passengerseat Refer to SEATS in chapter 3 fuel tank Refer to FUEL TANK in chapter
34. VVVVVVYVVY a Turn the adjusting knob 1 in direction or b Spring preload is Direction increased suspension is harder Spring preload is Direction 0 decreased suspension is softer Adjusting positions Minimum 0 turns in direction Standard 6 turns in direction Maximum 20 turns in direction with the adjusting knob fully turned in direction b Rebound damping CAUTION Never go beyond the maximum or minimum adjustment positions CHK ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY 1 Adjust rebound damping wwwvwvvvvvvvvvvvvvvvvvvvvevveww a Turn the adjusting screw 1 in direction a or b Rebound damping is Direction increased suspension is harder Rebound damping is Direction b decreased suspension is softer Adjusting positions Minimum 18 clicks in direction Standard 14 clicks in direction b Maximum 1 clicks in direction b with the adjusting screw fully turned in direction Compression damping fast compression damping CAUTION Never go beyond the maximum or minimum adjustment positions 1 Adjust fast compression damping wwwvwvvvvvvvvvvvvvvvvvvvvevvvw a Turn the adjusting bolt 1 in direction or 9 0 Com
35. cle 22 Pass the water hose lower side of the thermostat and between the ground lead and the neutral switch Install the leads so that the engine ground lead is posi tioned lower and the battery negative lead to be upper Install the protrusion of each lead to be above the vehicle Route the crankshaft position sensor lead under the wire har ness To the fuel pump Clamp the wire harness winding in and insert it to the frame hole CABLE ROUTING SPEC the battery band Press on the tip of the clamp after passing the leads through it R Insert the tail brake light lead to the rear frame hole Insert the clamp from the vehi cle front to the rear side and fas ten each lead coupler and onionhead to the fender rib and then point the tip of the clamp excessive part to the upper side of the vehicle Hold down the clamp tips after passing each lead P Pass the lead through inside of Make sure to position the cou pler at the downmost position of leads However the coupler should be set in the rear frame so that it is not caught by the seat bottom cover and other components V Point the tip of the clamp excessive part to
36. cylinder inside diameter 16 mm 0 63 in Caliper cylinder inside diameter 30 2 mm and 27 mm 1 19 in and 1 06 in CHASSIS SPECIFICATIONS SPEC Item Standard 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 Minimum Standard Maximum YZF R1S Spring Free length 260 mm 10 24 in 254 8 mm 10 03 in Coller length 42 mm 1 653 in eec Installed length 248 0 mm 9 76 in Spring rate K1 9 50 N mm 0 97 kg mm 54 22 Ib in Fork oil Recommended oil Suspension oil Ohlins R amp T 43 Quantity each front fork leg 0 43 L 0 38 Imp qt 0 45 US qt Level from the top of the outer tube 145 mm 5 71 in with the outer tube fully compressed and without the fork spring Spring preload adjusting positions Minimum 11 turns out Maximum 2 turns in from the standard position Rebound damping adjusting positions Minimum Standard Maximum Compression damping adjusting positions Minimum Standard Maximum from the fully turned in direction CHASSIS SPECIFICATIONS SPEC Item Standard 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 Spring rat
37. e K1 95 0 N mm 9 68 kg mm 542 18 Ib in Spring preload adjusting positions Minimum 0 Standard 6 Maximum 20 Rebound damping adjusting positions Minimum 18 Standard 14 Maximum 1 Compression damping adjusting positions fast compression damping Minimum Standard Maximum Compression damping adjusting positions slow compression damping Minimum Standard Maximum from the fully turned in direction Drive chain Model manufacturer 50VA8 DAIDO Link quantity 118 Drive chain slack 20 25 mm 0 79 0 98 in Maximum 15 link section 239 3 9 42 ELECTRICAL SPECIFICATIONS TIGHTENING TORQUES ELECTRICAL SPECIFICATIONS Item Standard Ignition system unit model manufacturer F8T82073 MITSUBISHI EUR AUS F8T82074 MITSUBISHI FRA Battery Manufacturer GS YUASA Ten hour rate amperage 0 9A TIGHTENING TORQUES ENGINE TIGHTENING TORQUES Thread Tightening torque size Exhaust pipe and exhaust valve pipe Bolt M6 assembly EXUP servo motor Bolt M6 Item Fastener Remarks Crankcase Bolt M6 Drive sprocket cover Bolt M6 Drive sprocket cover Bolt M6 Plate Bolt M6 TIGHTENING TORQUES Tightenin Item Thread g g Remarks Size mekg ftelb CHASSIS TIGHTENING TORQUES Horn bracket and under bracket M6 0 7 5 1 Connecting rod YZF R1S M6 0 8 58 Side cover and fuel tank M5 0 4 2 9 Front fork and
38. e pull rod When installing the clutch cover push the pull lever and check that the punch mark on the pull lever aligns with the mark b on the clutch cover Make sure that the pull rod teeth and pull lever shaft pinion gear are engaged 12 Tighten clutch cover bolts 1 12 Nm 1 2 8 7 feib clutch cover bolt 2 12 Nm 1 2 8 7 LOCTITE NOTE Tighten the clutch cover bolts in a stages and in a crisscross pattern 13 Adjust clutch cable free play Refer to ADJUSTING THE CLUTCH CABLE FREE PLAY in chapter 3 YZF R1 V YZF R1S V 2006 WIRING DIAGRAM 1 Main switch 2 A C magneto 3 Rectifier regulator 4 Fuse main 5 Fuse back up 6 Immobilizer unit 7 Battery Fuse fuel injection Starter relay 49 Starter motor 1 Starting circuit cut off relay 42 Neutral switch 43 Sidestand switch Fuel pump 5 ECU Ignition coil 1 Ignition coil 2 Ignition coil 3 Ignition coil 4 29 Spark plug Injector 1 2 Injector 2 Injector 3 Injector 4 25 Air induction system solenoid Sub throttle position sensor EXUP servo motor Speed sensor 29 Coolant temperature sensor Intake air temperature sensor 3 Crankshaft position sensor 82 Throttle position sensor 83 Intake air pressure sensor 82 Atmospheric pressure sensor 95 Cylinder identification sensor Lean angle sensor 87 Meter assembly 68 Immobilizer i
39. ed diagrams at the start of each removal and disassembly section 5 Numbers are given in the order of the jobs in the exploded diagram A circled number indicates a disassembly step Symbols indicate parts to be lubricated or replaced Refer to SYMBOLS A job instruction chart accompanies the exploded diagram providing the order of jobs names of parts notes in jobs etc Jobs requiring more information such as special tools and technical data are described sequentially CLUTCH CLUTCH COVER ENG CLUTCH ENG p REMOVING THE CLUTCH 1 Remove clutch cover 1 gasket 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 12 Nm 1 2 8 7 ftelb 2 Remove compression spring bolts 7 compression springs pressure plate 2 rod 3 3 Remove e friction plate 1 12 Nm 1 2 mekg 8 7 ft lb 10 Nm 1 0 mekg 7 2 115 4 Remove clutch plate 1 Job Part 2 AN gt friction plate 2 Removing the clutch cover Remove the parts in the order listed mioni heri 1 Refer to COWLINGS in chapter 3 Engine oil Drain Refer to CHANGING THE ENGINE OIL in chapter 3 Cover Clutch cable Disconnect Clutch cover Clutch cover gasket Dowel pin Oil filler cap
40. eplaced set it to 206 mm 8 11 in Tighten the connecting rod 1 1 and con necting rod 2 2 fully to the connecting rod arm 3 b Rotate the connecting rod 1 1 within one rotation so that the bearing is parallel At this time align the direction of bolt c Rotate the connecting rod arm 3 to adjust the connecting rod assembly length to 206 mm 8 11 in d Tighten the connecting rod bolt temporarily e Attach the connecting rod assembly to the vehicle and tighten the connecting rod bolt securely Connecting rod bolt i 8 Nm 0 8 mekg 5 8 ftelb SWINGARM AND DRIVE CHAIN CHAS 7 23 4 6 6 78 9 40474213101516 7 23 4 6 6 9101123 4 5 d6 12510204 12510302 55 CHECKING THE DRIVE CHAIN 1 Measure Measure the dimension between 15 links on the inner side 8 and outer side b of the roller and calculate the dimension between pin centers Dimension C between pin centers Inner dimension Outer dimension 6 2 15 link section of the drive chain Out of specification Replace the drive chain front drive sprocket and rear drive sprocket as a set 15 link drive chain sectio
41. ft side of the vehicle and cut the surplus sec tion Clamp the section between 0 and 20 mm 0 and 0 79 in from the split of the under bracket Clamp the leads inside the front fork of the vehicle Point the exit of the horn lead to the left front fork side Route two throttle cables behind the brake hose pass between the inside of the under bracket s upper side front fork and guide wire assembly and then pass it through the clamp that is inserted to the cover 3 under the frame 14 CABLE ROUTING SPEC H 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 1 Clamp should be positioned at the protector lower end of the brake hose and wrapped on the protector J Cut the tip leaving 2 to 4 mm 0 08 0 16 in 15 1 Wire harness 2 Crankshaft position sensor lead 3 Heat protector 4 Right handlebar switch lead 5 Positionin
42. g guide 6 Rear brake light switch lead 7 Coolant reservoir tank Speed sensor lead 9 Clutch cable 19 Radiator 1 Oil cooler outlet hose 2 Coolant reservoir tank drain hose CABLE ROUTING SPEC the frame and radiator stay Point the tip of the clamp excessive part to the front side of the vehicle Fasten the right handlebar switch lead with a clamp To the wire harness The clutch cable positioning guide should be above the upper end of the clamp Fasten the clutch cable with a clamp Refer to M Position relation between the clamp and guide 16 A Clamp it after passing between E Clamp the clamp upper end along the line of lower end of the hose clamp assembly Point the tip of the clamp excessive part to the front side of the vehicle Clutch cable is what the clamp fastens F The clutch cable doesn t project outside the water hose and the cylinder head in the box part in the figure To the engine Clamp behind the bracket 3 Cut the tip of the clamp solenoid lead and camshaft sensor lead should be con nected above the ignition coil sub wire harness and it should not drop on the cylinder head cover behind the ignition coil Pass the rig
43. garm vertical movement is smooth or if there is binding check the spacers bearings washers and dust cov ers DAAAAAAAAAAAAAAAAAAAAAAAAAAAA SWINGARM AND DRIVE CHAIN CHAS EAS00707 CHECKING THE SWINGARM YZF R1S 1 Check swingarm Bends cracks damage gt Replace 2 Check pivot shaft Roll the pivot shaft on a flat surface Bends Replace A WARNING Do not attempt to straighten a bent pivot shaft 3 Wash pivot shaft dust covers spacer washers bearings Recommended cleaning solvent Kerosene 4 Check dust covers 1 spacer 2 Damage wear Replace bearings 3 Damage pitting Replace 5 Check connecting rod assembly 4 Refer to CHECKING THE CONNECTING ROD ASSEMBLY relay arm 5 Damage wear Replace 6 Check bearings 6 oil seals 7 Damage pitting Replace 7 Check collars Damage scratches Replace 53 54 SWINGARM AND DRIVE CHAIN CHAS 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 Adjust Connecting rod assembly length STD 206 mm 8 11 in Adjust length 201 206 mm 7 91 8 11 in NOTE When the connecting rod assembly is removed disassembled and r
44. ht handlebar switch lead between the frame and heat protector CABLE ROUTING SPEC I The coupler for the air induction Coolant reservoir tank drain M Release the tip of the clamp and hose should cross with the speed sensor lead under the swingarm bracket Route the coolant reservoir tank drain hose over the up side of the vehicle Pass the rear brake light switch lead between the swingarm bracket and coolant reservoir tank 17 install it to the clutch cable Insert the clamp to the hole located on the right back side of the radiator Radiator fan motor lead should not be caught while inserting the clamp Push the clamp until it hits the radiator side stay Radiator fan motor lead should not be caught O Clamp the clutch cable so that it is within this specified clamp 1 Heat protector 2 Main switch lead 3 Left handlebar switch lead 4 Immobilizer lead 5 EXUP servo motor lead 6 Coolant reservoir tank drain hose 7 Fuel tank drain hose Coolant outlet pipe 9 Sidestand switch lead 19 Oil level switch lead 11 A C magneto lead 42 Fuse box stay 3 Water hose Stay 1 45 Chain case cover a AUS 4 gt UO g 7 g
45. icant Suspension oil Ohlins R amp T 43 12311310 45 FRONT FORK CHAS 4 Install dust seal 1 oil seal clip 2 oil seal 3 washer 4 CAUTION Make sure the numbered side of the oil seal faces up NOT E e Before installing the oil seal lubricate its lips with lithium soap based grease e Lubricate the outer surface of the inner tube with fork oil Before installing the oil seal cover the top the front fork leg with a plastic bag to protect the oil seal during installation 5 Install Oil seal 1 with the fork seal driver Fork seal driver 90890 01442 YM 01442 6 Install oil seal clip 1 NOTE LL Adjust the oil seal clip so that it fits into the outer tube s groove FRONT FORK CHAS 7 Install dust seal 1 with the fork seal driver weight Fork seal driver 90890 01442 YM 01442 8 Install rod puller 1 rod puller attachment 2 onto the damper rod 3 Rod puller 90890 01437 YM A8703 Rod puller attachment 90890 01435 YM A8703 9 Fill front fork leg with the specified amount of the recom mended fork oil Quantity each front fork leg 0 43 L 0 38 Imp qt 0 45 US qt Recommended oil Suspension oil Ohlins R amp T 43 Front fork leg oil level from the top of the outer tube with the outer tube fully compressed and without the fork spring 145 mm 5 71 in
46. idestand switch Check operation Front fork Check operation and for oil leakage Shock absorber assembly Check operation and shock absorber for oil leakage 28 AND LUBRICATION INTERVALS CHK ADJ ODOMETER READING x 1 000 km ANNUAL ITEM CHECK OR MAINTENANCE JOB 1 10 20 30 40 CHECK Rear suspension relay arm and connecting arm pivoting points Check operation E Fuel injection Adjust engine idling speed and synchronization NI J Engine oil Change Check oil level and vehicle for oil leakage Engine oil filter cartridge Replace Cooling system Check coolant level and vehicle for coolant leakage NI NI NI Change Every 3 years Front and rear brake switches Check operation Moving parts and cables Lubricate NI RI Throttle grip housing and cable Check operation and free play Adjust the throttle cable free play if necessary Lubricate the throttle grip housing and cable Air induction system Check the air cut off valve reed valve and hose for damage Replace any damaged parts if necessary Muffler and exhaust pipe Check the screw clamp for looseness EXUP system Check operation cable free play and pulley
47. increased suspension is harder Spring preload is Direction decreased suspension is softer Adjusting positions Minimum 11 turns in direction b Maximum 2 turns in direction from the standard position 30 31 CHK ADJUSTING THE FRONT FORK LEGS ADJ NOTE To find the standard position turn the adjusting bolt in direction a 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 b until the alignment marks match Turn the adjusting bolt 3 complete turns in direction b and be sure the alignment mark match This is the standard position 2 If the alignment mark on the adjusting bolt is positioned before the alignment mark on the front fork cap turn the adjusting bolt in direction b until the alignment marks match Turn the adjusting bolt 2 complete turns in direction b and be sure the alignment mark match This is the standard position Rebound damping CAUTION Never go beyond the maximum or minimum adjustment positions 1 Adjust rebound damping wwwwvwvvwvvvvvvvvvvvvvvvvvvvevveww a Turn the adjusting screw 1 in direction a or b Rebound damping is Direction increased suspension is harder Rebound damping is Direction b decreased suspension is
48. n limit maximum 239 3 mm 9 42 in NOTE measuring the 15 link section push down on the drive chain to increase its ten sion Perform this measurement at two or three dif ferent places 2 Check drive chain Stiffness Clean and lubricate or replace 3 Clean drive chain a Wipe the drive chain with clean cloth b Put the drive chain in kerosene and remove any remaining dirt c Remove the drive chain from the kerosene and completely dry it SWINGARM AND DRIVE CHAIN CHAS CAUTION This vehicle has a drive chain with small rubber O rings 1 between the drive chain side plates Never use high pressure water or air steam gasoline certain solvents 9 benzine or a coarse brush to clean the drive chain High pressure methods could force dirt or water into the drive 12310201 chain s internals and solvents will deterio rate the O rings A coarse brush can also damage the O rings Therefore use only kerosine to clean the drive chain 4 Check O rings 1 Damage Replace the drive chain drive chain rollers 2 Damage wear Replace the drive chain drive chain side plates 3 Damage wear Replace the drive chain Cracks Replace the drive chain and make sure that the battery breather hose is 1
49. ndard Clutch Friction plates Color code Thickness Plate quantity Color code Thickness Plate quantity Color code Thickness Plate quantity Clutch plates Thickness Plate quantity Max warpage Clutch springs Free length Red 2 9 3 1 mm 0 114 0 122 in 7 Red 2 9 3 1 mm 0 114 0 122 in 4 Red 2 9 3 1 mm 0 114 0 122 in 4 1 9 2 1 0 07 0 08 8 43 8 mm 1 72 in YZF R1S 2 8 0 110 2 8 0 110 2 8 0 110 0 1 mm 0 0039 in 41 6 mm 1 64 in Throttle bodies ID mark 5VY1 30 EUR AUS 5VY1 50 FRA CHASSIS SPECIFICATIONS SPEC CHASSIS SPECIFICATIONS Standard 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 DIABLO CORSA H PIRELLI YZF R1S Tire pressure cold 90 201 kg 198 443 Ib 250 kPa 2 5 kgf cm 2 5 bar 35 6 psi YZF R1 90 200 kg 198 441 Ib 250 kPa 2 5 kgf cm 2 5 bar 35 6 psi S YZF R1 Rear tire Model manufacture Pilot POWER Pilot POWER G MICHELIN YZF R1 D218G DUNLOP YZF R1 DIABLO CORSA PIRELLI YZF R1S Tire pressure cold 90 201 kg 198 443 Ib 290 kPa 2 9 kgf cm 2 9 bar 41 3 psi YZF R1 90 200 kg 198 441 Ib 290 kPa 2 9 kgf cm 2 9 bar 41 3 psi YZF R1S Front brakes Master
50. ndicator light 99 Fuel level warning light 49 Oil level warning light 41 Neutral indicator light 42 Tacho meter 43 Shift timing indicator light Multi function meter Engine trouble warning light Coolant temperature indicator light 6 Hi beam indicator light 48 Turn signal indicator light left light 49 Turn right Meter light 63 Oil level switch z Right handlebar switch Front brake light switch signal indicator Engine stop switch Start switch 50 Turn signal relay 67 Left handlebar switch 68 Hazard switch Pass switch Dimmer switch Horn switch 62 Clutch switch 63 signal switch Horn 65 Front turn signal light left Front turn signal light right 62 Rear turn signal light left Rear turn signal light right Headlight 79 Auxiliary light License light 2 Rear brake light switch 73 Tail brake light 74 Headlight relay on off 09 Headlight relay dimmer Fuse ignition 7 Fuse turn Fuse signal Fuse headlight 89 Anti safety alarm Radiator fan motor relay Fuse radiator fan motor left Fuse radiator fan motor right Radiator fan motor 2 Radiator fan motor 1 Ground COLOR CODE Brown Ch Chocolate Dg Dark green osa Green Gy Gray ER Blue Egi Light green DE Orange Pixels Pink Sb ests Sky blue W White Yellow B G Black Green B L Black Blue B R Black Red B W Black White B Y Black Yellow Br G Brown Green B
51. ng 3 Fuel tank drain hose 4 Fuel tank breather hose 5 Clip 6 Air filter stay 7 Fuel hose 2 3 way connector 9 Pipe 19 Fuel tank bracket 1 Fuel hose clamp 12 Fuel hose 1 3 Fuel pump assembly CABLE ROUTING SPEC A Install the lip of O ring facing Fuel piping connector attach upward Install the part pointing the white paint part of the hose to the left side of the vehicle Any direction of the clip grip can be accepted D Install the clip grip as specified in the drawing Install the part pointing the white paint part of the hose to the left side of the vehicle Point the clip grip to the left side of the vehicle ment directions fuel pump side Always use hands to connect disconnect the connector with out using tool Insert the connector until the click sound is heard and check that the connector does not come off Make sure that no for eign matter is caught in the sealing section It is prohibited to wear the cotton work gloves or equivalent coverings This part works as a dropout stopper 26 After Item 1 mentioned above is finished check that the clamp is inserted from the down side and and sections are perfectly equipped
52. ng it behind displacement of the tube Q Route the coolant reservoir tank the water pump breather hose Route by the outside of vehicle drain hose so that it is routed at The lengths of two hose ends away from the water hose the innermost position to each are allowed to be random Any L Point the tip of the clamp hose and lead direction of cut edges can be excessive part to the down Arrange so as not for each hose accepted Only for the fuel tank rear side of the vehicle Fasten to cross in the part between drain hose the wire harness with a clamp from the section AA Clamp the fuel tank drain hose The outside of the vehicle which is in the illustration and fuel tank breather hose Innermost section of the vehi S Align the molded part of the fuel Route the lead by the inside of cle tank drain hose with the stay 1 the water hose and water pipe Can be routed in any order lt gt IT 7 I CABLE ROUTING SPEC T Routing of the fuel tank drain hose EXUP servo motor oil level switch sidestand switch leads are omitted in this draw ing
53. nual where applicable NOTE Designs and specifications are subject to change without notice EAS00004 IMPORTANT MANUAL INFORMATION Particularly important information is distinguished in this manual by the following A The Safety Alert Symbol means ATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED A WARNING Failure to follow WARNING instructions could result in severe injury or death to the vehicle operator a bystander or a person checking or repairing the vehicle CAUTION A CAUTION indicates special precautions that must be taken to avoid dam age to the vehicle NOTE A NOTE provides key information to make procedures easier or clearer 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 D The manual is divided into chapters An abbreviation and symbol in the upper right corner of each page indicate the current chapter Refer to SYMBOLS Each chapter is divided into sections The current section title is shown at the top of each page except in Chapter PERIODIC CHECKS AND ADJUSTMENTS where the sub section title s appears Sub section titles appear in smaller print than the section title 4 To help identify parts and clarify procedure steps there are explod
54. o loosen the engine mounting adjust bolts For installation reverse the removal procedure 58 59 Mur INSTALLING THE ENGINE 1 Install engine mounting adjust bolts temporary tighten 2 Install engine 3 Install e lower engine mounting bolt 1 upper engine mounting bolt 2 self locking nuts NOTE Lubricate the lower and upper engine mount ing bolts threads with lithium soap based grease 4 Install left front engine mount bolt 1 temporary tighten 5 Install engine mount collar inside 1 engine mount collar outside 2 right front engine mount bolt 3 temporary tighten engine mount collar inside outside 4 engine mount collar center 5 YZF R1 YZF R1S 6 Tighten engine mounting adjust bolts Nm 0 7 5 1 Use the pivot shaft wrench 1 and pivot shaft wrench adapter 2 to tighten the engine mounting adjust bolts aene EN Pivot shaft wrench 90890 01471 YM 01471 Pivot shaft wrench adapter 90890 01476 7 Tighten upper self locking nut 1 lower self locking nut 2 51 Nm 5 1 37 ftelb NOTE C First tighten the lower self locking nut and then tighten the upper self locking nut 8 Tighten left front engine mounting bolt 1 45 Nm 4 5 33 9 Tighten right
55. position Lights signals and switches Check operation Adjust headlight beam NOTE e Air filter e This model s air filter is equipped with a disposable oil coated paper element which must not be cleaned with compressed air to avoid damaging it air filter element needs to be replaced more frequently when riding in unusually wet dusty areas e Hydraulic brake service Regularly check and if necessary correct the brake fluid level Every two years replace the internal components of the brake master cylinders and calipers and change the brake fluid Replace the brake hoses every four years and if cracked or damaged 29 CHK ADJUSTING THE FRONT FORK LEGS ADJ EAS00155 CHASSIS ADJUSTING THE FRONT FORK LEGS YZF R1S The following procedure applies to both of the front fork legs A WARNING Always adjust both front fork legs evenly Uneven adjustment can result in poor han dling and loss of stability 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 Adjust spring preload wwwvwvvvvvvvvvvvevvvvvvvvvevvewvw a Turn the adjusting bolt 1 in direction b NOTE 77777 7 Be sure to align the alignment mark on the adjusting bolt with the alignment mark on the front fork cap Spring preload is Direction
56. pression damping is N 7 Direction increased suspension is 2 harder Compression damping is 7 Direction b decreased suspension is softer 2 NW Adjusting positions Minimum 42 clicks in direction Standard 30 clicks in direction b Maximum 1 clicks in direction b with the adjusting screw fully turned in direction 34 CHK ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY 35 Compression damping slow compression damping CAUTION Never go beyond the maximum or minimum adjustment positions 1 Adjust slow compression damping VVVVVVVVVVVVVVVVVVVVVVVVVVVVY a Turn the adjusting screw 1 in direction or b Compression damping is Direction 2 increased suspension is harder Compression damping is Direction 0 decreased suspension is softer Adjusting positions Minimum 17 clicks in direction Standard 10 clicks in direction b Maximum 1 clicks in direction b with the adjusting screw fully turned in direction FRONT WHEEL AND BRAKE Discs CHAS 00514 CHASSIS FRONT WHEEL AND BRAKE DISCS YZF RIS Nm 06 43 Feb 6 Nm 0 6 mekg 4 3 ftelb 91 Nm 9 1 mekg 66 ftelb
57. r L Brown Blue Br R Brown Red Br W Brown White G B Green Black G W Green White G Y Green Yellow Gy B Gray Black Gy G Gray Green Gy R Gray Red L B Blue Black L R Blue Red L W Blue White L Y Blue Yellow O B Orange Black O G Orange Green P W Pink White R B Red Black R G Red Green R L Red Blue R W Red White R Y Red Yellow Sb W Skyblue White W B White Black W R White Red W Y White Yellow Y B Yellow Black Y G Yellow Green Y L Yellow Blue Y R Yellow Red Yellow White YAMAHA YAMAHA MOTOR LTD 2500 SHINGAI IWATA SHIZUOKA JAPAN YZF R1 V YZF R1S 2006 YZF R1 V YZF R1S 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
58. rratic clutch operation 2 Check clutch boss Cracks damage Replace EAS00286 CHECKING THE PRESSURE PLATE 1 YZF R1S 1 Check pressure plate 1 Cracks damage Replace bearing 2 Damage wear Replace 71 SN auno ENG ep CHECKING THE PULL LEVER SHAFT AND PULL ROD YZF R1S 1 Check pull lever shaft pinion gear teeth 1 pull rod teeth 2 Damage wear Replace the pull rod and pull lever shaft pinion gear as a set 11412102 2 Check pull rod bearing Damage wear Replace INSTALLING THE CLUTCH YZF R1S 1 Install clutch housing 1 conical spring washer e thrust plate 2 NOTE Align the projection of clutch housing 8 and hollow of the oil pump drive gear b 2 Install pressure plate 2 1 clutch boss 2 nA ll Fit the groove of the pressure plate 2 to the projection b of the clutch boss to assemble 72 73 ases ENG 3 Install spring 1 clutch boss nut 2 P 95 Nm 8 5 m kg 69 fiib NOTE Put the spring detent into the groove of the pressure plate 2 Assemble so that each spring detent a is positioned in a different groove While holding the clutch boss 3 with the clutch holding tool tighten the clutch boss nut Lock the threads on the clutch boss nut by staking them with a drift punch at the point aligned
59. ssembly muffler protector Refer to EXHAUST PIPE in chapter 5 rear cowling upper bottom cowling Refer to COWLINGS in chapter fuel tank Refer to FUEL TANK in chapter rider seat and passenger seat Refer to SEATS in chapter 3 51 52 SWINGARM AND DRIVE CHAIN CHAS 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 Place the vehicle on a suitable stand so that the rear wheel is elevated 2 Remove rear wheel rear shock absorber Refer to REMOVING THE REAR WHEEL and REMOVING THE REAR SHOCK ABSORBER ASSEMBLY coolant reservoir tank NOTE When removing the rear shock absorber assembly lower bolt hold the swingarm so that it does not drop down 3 Measure swingarm side play swingarm vertical movement wwwvwvvvvvvvvvvvvvvvvvvvvevveww a Measure the tightening torque of the pivot shaft nut Y Pivot shaft nut A 105 Nm 10 5 m kg 76 ft Ib b Measure the swingarm side play by moving the swingarm from side to side c If the swingarm side play is out of specifica tion check the spacers bearings washers and dust covers Swingarm side play at the end of the swingarm 1 0 mm 0 04 in d Check the swingarm vertical movement by moving the swingarm up and down If swin
60. the inside of the vehicle Fasten the wire har ness with a clamp 23 excessive part to the rear side of the vehicle Fasten the starter relay lead turn signal relay lead main fuse lead main fuse lead from the battery positive lead and starting circuit cut off relay lead with a clamp Route each lead upper side the wire harness Fasten the wire harness battery negative lead and starter motor lead with a clamp Point the tip of the clamp excessive part to the inside of the vehicle CABLE ROUTING SPEC the tip of the clamp Z Point the tip of the clamp DD Fasten the wire harness excessive part to the down side of the vehicle Fasten the wire harness battery negative lead A C magneto lead and starter motor lead with a clamp AA the speed sensor BB Insert the wire harness wrap ping clamp to the hole of the frame CC After passing the lead between the wire harness and starter motor leads fastening by the clamp should be cancelled and route the lead under the idle remote controller A C magneto lead and throt tle body lead with a clamp Point the tip of the clamp cut the tip of the clamp leaving 2

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