FOREWORD
This Supplementary Service Manual has been prepared to introduce new service and data for the YZF-R1 2000. For complete service information procedures it is necessary to use this Supplementary Service Manual together with the following manual. YZF-R1 SERVICE MANUAL: 4XV1-AE1

YZF-R1 2000 SUPPLEMENTARY SERVICE MANUAL E1999 by Yamaha Motor Co., Ltd. First Edition, December 1999 Any reproduction or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited.

Repair and maintenance work attempted by anyone without this knowledge is likely to render the vehicle unsafe and unfit for use. Ltd. Yamaha Motor Company.EB001000 NOTICE This manual was produced by the Yamaha Motor Company. primarily for use by Yamaha dealers and their qualified mechanics. EB002000 IMPORTANT MANUAL INFORMATION Particularly important information is distinguished in this manual by the following. The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! WARNING Failure to follow WARNING instructions could result in severe injury or death to the motorcycle operator. 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. CAUTION: NOTE: . Modifications and significant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will appear in future editions of this manual where applicable. Ltd. it is not possible to include all the knowledge of a mechanic in one manual. A CAUTION indicates special precautions that must be taken to avoid damage to the motorcycle. NOTE: Designs and specifications are subject to change without notice. Therefore. a bystander or a person checking or repairing the motorcycle. is continually striving to improve all of its models. A NOTE provides key information to make procedures easier or clearer.

Refer to “SYMBOLS”. 1 The manual is divided into chapters. 6 2 1 3 4 5 8 7 . except in Chapter 3 (“PERIODIC CHECKS AND ADJUSTMENTS”). etc. easy-to-read reference book for the mechanic. A circled number indicates a disassembly step. there are exploded diagrams at the start of each removal and disassembly section. assembly. names of parts. disassembly. providing the order of jobs. 4 To help identify parts and clarify procedure steps. Comprehensive explanations of all installation. An abbreviation and symbol in the upper right corner of each page indicate the current chapter. removal. 6 Symbols indicate parts to be lubricated or replaced. 5 Numbers are given in the order of the jobs in the exploded diagram. 7 A job instruction chart accompanies the exploded diagram. Refer to “SYMBOLS”. notes in jobs. The current section title is shown at the top of each page. 2 Each chapter is divided into sections. 3 Sub-section titles appear in smaller print than the section title. repair and check procedures are laid out with the individual steps in sequential order. where the sub-section title(-s) appears. 8 Jobs requiring more information (such as special tools and technical data) are described sequentially.EB003000 HOW TO USE THIS MANUAL This manual is intended as a handy.

Symbols 1 to 9 indicate the subject of each chapter. 10 11 12 13 14 15 16 17 TRBL SHTG 11 12 Serviceable with engine mounted Filling fluid Lubricant Special tool Tightening torque Wear limit.EB004000 1 2 SYMBOLS The following symbols are not relevant to every vehicle. 24 Apply locking agent (LOCTITE®) 25 Replace the part . 18 19 20 21 22 23 21 22 23 Engine oil Gear oil Molybdenum disulfide oil Wheel bearing grease Lithium soap base grease Molybdenum disulfide grease 24 25 Symbols 24 to 25 in the exploded diagrams indicate the following. clearance Engine speed Electrical data 13 14 15 16 17 18 19 20 Symbols 18 to 23 in the exploded diagrams indicate the types of lubricants and lubrication points. 1 2 3 4 5 6 7 8 9 General information Specifications Periodic checks and adjustments Engine Cooling system Carburetor(-s) Chassis Electrical system Troubleshooting GEN INFO 3 SPEC 4 CHK ADJ 5 6 ENG COOL 7 CARB 8 CHAS 9 ELEC 10 Symbols 10 to 17 indicate the following.

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .CONTENTS SPECIFICATIONS GENERAL SPECIFICATIONS . AIR FILTER CASE AND IGNITION COIL PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE AIR INDUCTION SYSTEM . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE FRONT WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE TIGHTENING TORQUES . . . . . . . . . . . . CHASSIS TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AIR CUTOFF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 2 6 9 11 11 12 13 13 14 17 20 PERIODIC CHECKS AND ADJUSTMENTS INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 33 35 36 OVERHAULING THE ENGINE AIR INDUCTION SYSTEM . . . . . . . . . CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . OIL FLOW DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . ELECTRICAL SPECIFICATIONS . . . . . . . . . . COWLINGS . . . . . . . . . . . . . . . . . 47 47 47 48 49 CHASSIS FRONT WHEEL AND BRAKE DISCS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AIR INDUCTION SYSTEM DIAGRAMS . . . . . . . . . . . . . PERIODIC MAINTENANCE AND LUBRICATION INTERVALS . . . . . . . . . . . . . . . . . . . . . . . . . . CABLE ROUTING . . . . . . . . . . . . . . . . . . . . . . . . . LUBRICATION POINTS AND LUBRICANT TYPES . . . . . . . . . . . . . . . . . . ENGINE . . . . . . . . . . . . . . . . . . . . COOLANT FLOW DIAGRAMS . . . . . . . . . FRONT AND REAR BRAKES . . . . . . . . . . . . . . . . . . . . CHASSIS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ASSEMBLING THE CRANKCASE . . . 37 38 39 40 41 43 COOLING SYSTEM RADIATOR . . . . . . ENGINE LUBRICATION POINTS AND LUBRICANT TYPES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE SPECIFICATIONS . . . . . . . . . . 45 CARBURETORS AIR INDUCTION SYSTEM . . . . . . . . . . TIGHTENING TORQUES . . . . REAR BRAKE MASTER CYLINDER AND BRAKE FLUID RESERVOIR . . . . . . . . . . . . . . . . . . . . . . . . 50 51 52 52 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AIR INJECTION . . . . . . . . .

. . . . . . . . . . . . COOLANT TEMPERATURE WARNING LIGHT . . . . TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . CIRCUIT DIAGRAM . . . . . . . . . . . . . . ELECTRIC STARTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ELECTRICAL INSTRUMENT FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . SELF-DIAGNOSIS . . . . . STARTER MOTOR . . . . . . . . TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEEDOMETER UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . YZF-R1 WIRING DIAGRAM (For EUR) YZF-R1 WIRING DIAGRAM (For OCE) 53 53 54 55 57 57 62 62 63 66 67 . . . . . . . . . . . . . . . . . . . . . . . . INDICATOR LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

035 mm 2.105 mm 815 mm 1. passenger.400 mm 194 kg 175 kg 201 kg SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS Limit –1– . and accessories) Standard 2.395 mm 140 mm 3. rider.GENERAL SPECIFICATIONS SPEC SPECIFICATIONS GENERAL SPECIFICATIONS Item Dimensions Overall length Overall width Overall height Seat height Wheelbase Minimum ground clearance Minimum turning radius Weight Wet (with oil and a full fuel tank) Dry (without oil and fuel) Maximum load (total of cargo.095 mm (for AUS) 695 mm 1.

100 r/min (0. SPEC Standard Liquid-cooled.5 kgf/cm2) at 400 r/min SSS SSS SSS SSS SSS SSS SSS SSS Limit Regular unleaded gasoline Unleaded fuel (for AUS) 18 L 3. DOHC 998 cm3 Forward-inclined parallel 4-cylinder 74 58 mm 11.9 L 45 kPa at 1.000 X 1.3 kPa (220 mm Hg) 1.7 L 2.7 kgf/cm2) SSS SSS SSS SSS SSS SSS –2– . 4-stroke.45 kgf/cm2 at 1.8 : 1 1.6 L 2.100 r/min) 490 X 570 kPa (4.100 r/min 29.8 L Wet sump SSS SSS SSS SSS SSS SAE20W40SE or SAE10W30SE Quantity Total amount Without oil filter cartridge replacement With oil filter cartridge replacement Oil pressure (hot) Relief valve opening pressure 3.9 X 5.450 kPa (14.ENGINE SPECIFICATIONS ENGINE SPECIFICATIONS Item Engine Engine type Displacement Cylinder arrangement Bore stroke Compression ratio Engine idling speed Vacuum pressure at engine idling speed Standard compression pressure (at sea level) Fuel Recommended fuel Fuel tank capacity Total (including reserve) Reserve only Engine oil Lubrication system Recommended oil Temp.

4 mm 24.85 mm SSS Measurement A Measurement B Measurement C Max.65 mm 32.5 X 32.05 mm 7.75 X 7.85 mm 24.472 mm 0.95 X 25.45 X 7.521 mm 24.500 X 24.062 mm SPEC Limit SSS SSS SSS SSS Measurement A Measurement B Measurement C Exhaust camshaft lobe dimensions 32.03 mm –3– .459 X 24.05 mm 24.85 mm SSS 0.95 mm SSS 32.05 mm 7.6 mm 24.95 X 33.95 X 25. camshaft runout 32.ENGINE SPECIFICATIONS Item Camshafts Drive system Camshaft cap inside diameter Camshaft journal diameter Camshaft-journal-to-camshaftcap clearance Intake camshaft lobe dimensions Standard Chain drive (right) 24.028 X 0.

1 mm 24.012 mm 4.1 mm 0.21 X 0.500 X 4.1 mm 0.05 mm 4. valve seats.01 mm Valve seat width Intake Exhaust Connecting rods Crankshaft-pin-to-big-end-bearing clearance Bearing color code 0.9 mm 0.55 mm 0.9 mm 3.1 mm 0.76 X 2.ENGINE SPECIFICATIONS Item Valves.90 mm 0.20 mm 0.037 mm 0. valve guides Valve clearance (cold) Intake Exhaust Valve dimensions Standard SPEC Limit 0.000 X 4.512 mm 0.9 X 1.6 mm 1.08 mm 0.945 mm 4.465 X 4.9 X 1.990 mm 4.975 X 3.5 X 0.047 mm SSS SSS SSS SSS SSS SSS SSS SSS SSS 3.055 mm –1 = Violet 0 = White 1 = Blue 2 = Black SSS SSS SSS SSS –4– .90 mm 1.9 X 1.480 mm 4.25 mm SSS SSS Head Diameter Face Width Seat Width Margin Thickness Valve head diameter A Intake Exhaust Valve face width B Intake Exhaust Valve seat width C Intake Exhaust Valve margin thickness D Intake Exhaust Valve stem diameter Intake Exhaust Valve guide inside diameter Intake Exhaust Valve-stem-to-valve-guide clearance Intake Exhaust Valve stem runout 22.76 X 2.1 mm 0.031 X 0.010 X 0.43 mm 4.11 X 0.020 X 0.1 mm 0.9 X 1.9 X 23.4 X 24.5 X 0.

drive axle runout Carburetors Model (manufacturer) quantity Throttle cable free play (at the flange of the throttle grip) ID mark Main jet Main air jet Jet needle Needle jet Pilot air jet Pilot outlet Pilot jet Bypass 1 Bypass 2 Bypass 3 Pilot screw turns out Valve seat size Standard Constant mesh. 6-speed Spur gear 68/43 (1.333) 30/25 (1.500) 28/21 (1.842) 30/20 (1.115) SSS SSS BDSR40 (MIKUNI) 3 X 5 mm 4 SPEC Limit SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS 0.500) 35/19 (1.8 0.581) Chain drive 43/16 (2.08 mm 0. main axle runout Max.688) Left-foot operation 35/14 (2.5 –5– .9 0.ENGINE SPECIFICATIONS Item Transmission Transmission type Primary reduction system Primary reduction ratio Secondary reduction system Secondary reduction ratio Operation Gear ratios 1st gear 2nd gear 3rd gear 4nd gear 5th gear 6th gear Max.0 #15 0.08 mm SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS 5JJ1 00 #130 Carburetors 1 and 4: #60 Carburetors 2 and 3: #65 6DEY5-53-3 P-OM #120 1.200) 29/26 (1.8 3.125 1.

tire tread depth Rear brake Brake type Operation Brake pedal position (from the top of the brake pedal to the bottom of the rider footrest bracket) Recommended fluid Brake discs Diameter thickness Min. thickness Max.7 mm 38.6 mm SSS SSS SSS SSS SSS 4. 2.5 mm 0.5 bar) 290 kPa (2. tire tread depth Rear tire Tire type Size Model (manufacturer) Tire pressure (cold) 0 X 90 kg 90 X 197 kg High-speed riding Min.2 mm SSS SSS –6– .5 kg/cm2.5 kg/cm2. 2. 2.5 bar) 250 kPa (2.5 kg/cm2.5 bar) SSS SPEC Limit SSS SSS SSS SSS SSS SSS 1.5 mm SSS SSS SSS 1.9 kg/cm2. 2. 2.9 bar) 250 kPa (2.5 kg/cm2. deflection Brake pad lining thickness Standard Tubeless 120/70 ZR17 (58W) MEZ3Y FRONT (METZELER) D207FQ (DUNLOP) 250 kPa (2. 2.1 mm 0.5 mm Master cylinder inside diameter Caliper cylinder inside diameter 12.6 mm Tubeless SSS 190/50 ZR17 (73W) SSS MEZ3Y (METZELER)/D207N (DUNLOP) SSS 250 kPa (2.5 bar) SSS Single-disc brake Right-foot operation 35 X 40 mm DOT 4 245 5 mm SSS SSS 5.5 kg/cm2.5 bar) 250 kPa (2.CHASSIS SPECIFICATIONS CHASSIS SPECIFICATIONS Item Front tire Tire type Size Model (manufacturer) Tire pressure (cold) 0 X 90 kg 90 X 197 kg High-speed riding Min.

75 kgf/mm) 0 X 135 mm No Suspension oil “01” or equivalent 482 cm3 74 mm SPEC Limit SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS 11 mm SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS 8 6 1 11 5 1 9 5 1 –7– .CHASSIS SPECIFICATIONS Item Front suspension Suspension type Front fork type Front fork travel Spring Free length Spacer length Installed length Spring rate (K1) Spring stroke (K1) Optional spring available Fork oil Recommended oil Quantity (each front fork leg) Level (from the top of the inner tube.35 N/mm (0.4 mm 7. with the inner tube fully compressed. and without the fork spring) Damper adjusting rod locknut distance Spring preload adjusting positions Minimum Standard Maximum Rebound damping adjusting positions Minimum* Standard* Maximum* Compression damping adjusting positions Minimum* Standard* Maximum* *with the adjusting screw fully turned in position Standard Telescopic fork Coil spring/oil damper 135 mm 255 mm 85 mm 242.

4 N/mm (7.CHASSIS SPECIFICATIONS Item Rear suspension Suspension type Rear shock absorber assembly type Rear shock absorber assembly travel Spring Free length Installed length Spring rate (K1) Spring stroke (K1) Optional spring available Standard spring preload gas/air pressure Spring preload adjusting positions Minimum Standard Maximum Rebound damping adjusting positions Minimum* Standard* Maximum* Compression damping adjusting positions Minimum* Standard* Maximum* *with the adjusting screw fully turned in position Standard Swingarm (link suspension) Coil spring/gas-oil damper 65 mm SPEC Limit SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS 176 mm 162.5 mm 78.200 kPa (12 kgf/cm2) 1 4 9 11 7 1 11 9 1 –8– .84 kgf/mm) 0 X 65 mm No 1.

1 X 14.5 mm Full-transistor FE246BH (DENSO) No 75 X 95 cycles/min.009 X 0.011 Ω 24. 21 W 2 4XV (DENSO) G8R-30Y-M (OMRON) 2 2 12 V Transistorized coil ignition 5_ BTDC at 1.ELECTRICAL SPECIFICATIONS ELECTRICAL SPECIFICATIONS Item System voltage Ignition system Ignition system type Ignition timing Advanced timing Advancer type Pickup coil resistance/color Transistorized coil ignition unit model (manufacturer) Voltage regulator Regulator type Model No-load regulated voltage Bulbs (voltage/wattage Headlight Auxiliary light Tail/brake light Turn signal light Meter light Electric starting system System type Starter motor Model (manufacturer) Power output Brushes Overall length Spring force Commutator resistance Commutator diameter Mica undercut Turn signal relay Relay type Model (manufacturer) Self-cancelling device built-in Turn signal blinking frequency Wattage Oil level switch model (manufacturer) Fuel pump relay model (manufacturer) quantity) 12 V 60 W/55 W 12 V 5 W 2 12 V 5 W/21 W 12 V 21 W 4 LED Constant mesh 5JJ (YAMAHA) 0.75 kW 9.5 mm 1.9 V SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS 3.32 N (488 X 732 gf) 0.65 mm SSS SSS 23.8 mm 4.050 r/min 55_ BTDC at 5.000 r/min Throttle position sensor and electrical 248 X 372 W/Gy-B TNDF54 (DENSO) Standard SPEC Limit SSS SSS SSS SSS SSS SSS SSS Semiconductor short circuit SH650A-12 14.88 X 7.5 mm SSS SSS SSS SSS SSS SSS SSS SSS –9– .

ELECTRICAL SPECIFICATIONS Item Thermo unit Model (manufacturer) Fuses (amperage quantity) Main fuse Headlight fuse Signaling system fuse Ignition fuse Radiator fan fuse Backup fuse (odometer) Reserve fuse Standard 5JJ (NIPPON THERMOSTAT) 30 A 20 A 20 A 15 A 10 A 10 A 30 A 20 A 15 A 10 A 1 1 1 1 1 1 1 1 1 1 SPEC Limit SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS –10– .

0 6.4 See NOTE 14 1.5 mSkg).4 7 0.5 1. tighten another 45_ X 50_ –11– .2 Remarks 4 0.7 NOTE: After tightening to 15 Nm (1.TIGHTENING TORQUES TIGHTENING TORQUES ENGINE TIGHTENING TORQUES Item Cylinder head Cylinder head Generator rotor Oil/water pump assembly driven sprocket cover Air induction system hose Crankcase Crankcase Crankcase Crankcase Ignitor unit Fastener Nut Cap nut Bolt Bolt Clamp Bolt Bolt Bolt Bolt Screw Thread size M10 M10 M10 M6 M7 M9 M6 M6 M8 M5 Q’ty y 8 2 1 1 4 10 2 14 2 2 SPEC Tightening torque Nm 50 65 65 12 mSkgf 5.4 12 1.2 24 2.5 6.

Retighten the ring nut to specification.5 2.4 2. tighten the ring nut to approximately 18 Nm (1.4 1.9 4. NOTE: 1.0 5.8 mSkg) with a torque wrench. then loosen the ring nut completely. 2.8 Remarks See NOTE.TIGHTENING TORQUES CHASSIS TIGHTENING TORQUES Item Lower ring nut Engine mounting Front mounting bolts Rear upper mounting bolt Rear under mounting bolts Pinch bolts Exhaust pipe bracket Rear master cylinder Thread size M30 M10 M10 M10 M8 M8 M8 SPEC Tightening Nm 9 40 55 55 24 24 18 mSkgf 0. First.5 5. –12– .

LUBRICATION POINTS AND LUBRICANT TYPES E202000 SPEC LUBRICATION POINTS AND LUBRICANT TYPES ENGINE LUBRICATION POINTS AND LUBRICANT TYPES Lubrication point Connecting rod bolts and nuts Lubricant –13– .

OIL FLOW DIAGRAMS EB203000 SPEC OIL FLOW DIAGRAMS 1 2 3 4 5 6 7 Intake camshaft Exhaust camshaft Crankshaft Oil cooler Oil pipe Oil strainer Oil pump –14– .

OIL FLOW DIAGRAMS 1 Exhaust camshaft 2 Intake camshaft 3 Oil filter SPEC –15– .

OIL FLOW DIAGRAMS 1 Cylinder head 2 Crankshaft SPEC –16– .

COOLANT FLOW DIAGRAMS EB203000 SPEC COOLANT FLOW DIAGRAMS 1 2 3 4 5 6 Thermostat Radiator cap Coolant reservoir Radiator Oil cooler Water jacket joint –17– .

COOLANT FLOW DIAGRAMS 1 2 3 4 SPEC Thermostat housing Water pump Radiator Radiator fan –18– .

COOLANT FLOW DIAGRAMS 1 Radiator 2 Thermo unit SPEC –19– .

C The speedometer lead with not be tighten. –20– .CABLE ROUTING EB206000 SPEC CABLE ROUTING 1 2 3 4 5 Clutch cable Left handlebar switch lead Starter cable Main switch lead Steering cover A Properly insert the meter assembly coupler and rubber boot into the meter assembly. D Install the headlight relays onto the headlight housing bridge. F Route the turn signal leads upper the headlight housing boss. B Route the meter assembly lead through the left side of the headlight housing. E Connect to the right front turn signal connectors.

CABLE ROUTING G Fasten the headlight lead with a plastic clamp at white tape mark. J Route the throttle cable to the front side of the brake hose. I Route the headlight lead through the plastic guide. L Make sure that the horn leads face out. O Route the right handlebar switch lead behind the throttle cables. P Route the right handlebar switch lead in front of the throttle cables. SPEC N Route the thermo switch / temperature sender subwire harness to the outside of the radiator cap. K Route the clutch cable behind the front fork leg. H Fasten the wire harness to the headlight housing boss with a plastic locking tie. M Route the throttle cables and right handlebar switch lead between the lower bracket and steering cover. Do not cross the throttle cables and the right handlebar switch lead. –21– .

CABLE ROUTING Rollover valve (California only) Charcoal canister (California only) Rear brake switch lead Timing chain tensioner. B 0 X 5 mm 1 2 3 4 5 6 7 8 9 SPEC C Route the rollover-valve-to-fuel-tank hose to the inside of the fuel hose (California only). F Route the clutch cable between the radiator bracket and frame and in front of the thermostat assembly breather hose. Thermostat assembly breather hose Radiator inlet hose Coolant reservoir breather hose Clutch cable Pickup coil lead A Fasten the starter motor lead to the flame which is just before the side cover stay (0 X 5 mm) with a plastic clamp. D Route the coolant reservoir breather hose over the timing chain tensioner. –22– . H Insert the plastic clamp into the hole in the coolant reservoir’s tab. E Insert the plastic clip through the hole in the plastic frame panel and then fasten the wire harness and coolant reservoir breather hose with it. G Route the clutch cable to the inside of the radiator inlet hose.

coolant reservoir tank breather. –23– . moreover at under the three sides pipe. fuel tank breather hose.CABLE ROUTING 1 Starter cable 2 Air induction system vacuum 3 4 5 6 7 8 9 10 11 12 13 14 15 SPEC hose Air induction system hose Sidestand switch lead Oil level switch lead Clamp Right handlebar switch lead Throttle cables Air guide Air filter case breather hose Coolant reservoir breather hose Fuel tank overflow hose and fuel tank breather hose Drive chain sprocket cover Coolant hose EXUP servomotor A Route the air filter case breather hose and air induction system hose to the inside of the wire harness. clamp all of them at just behind of the air induction system protector and air induction system vacuum hose protector. air induction system hose and air induction system vacuum hose outside of the AC magneto lead. B Through the air cleaner drain hose. fuel tank over flow hose. Then.

K Do not crush the water pump breather hose and Make sure the rear flasher light lead coupler and plastic clip. tail light lead coupler in the rubber cover. L Pass the fuel tank breather hose and the air filter G Route the rear turn signal lead through the hole in the drain hose through the steel clamps and then after upper rear fender. J Route the sidestand switch lead and oil level switch Route the seat lock cable over the wire harness. I Fasten the sidestand switch lead. lead to the inside of the drive sprocket cover. routing the hoses to the exterior of the under cowlH 50 mm ing. Fasten the wire harness with a plastic clamp. engine oil level M Route the engine oil level switch lead and sideswitch lead. and water pump breather hose with a stand switch lead inside the coolant hose. align the leading ends of the hoses. –24– .CABLE ROUTING C D E F SPEC To the connector cover. plastic clip.

Clamp under a three sides pipe.CABLE ROUTING N Pass the fuel tank breather hose and the air filter Q drain hose through the inside of the coolant hose. –25– .V ant reservoir tank breather hose. SPEC To the air filter. Insert the fuel tank breather hose into a back side nipple of fuel tank. cool. Insert the fuel tank over flow hose into a front side nipple of fuel tank. Adjust the all clip’s direction to back side of the body. To the air vent surge tank. S O Pass the air filter drain hose and the coolant reservoir hose through the inside of the coolant hose and route the leading ends to the bottom of the T coolant hose. coolant hose. fuel tank drain hose and air induction system W hose at the steel clamp. The leading ends must not protrude from the under cowling. To the fuel tank. fuel tank breather hose. R No hose must be inserted into the under cowling. The fuel tank nipple and the fuel tank breather hose have each white mark. U P Fasten the air filter drain hose.

E Fasten the EXUP cables and engine mount with a plastic locking tie.CABLE ROUTING Speed sensor lead Charcoal canister (California only) EXUP cables EXUP A Route the EXUP cables behind the cross tube. –26– . C Route the EXUP cables on the outside of the engine mount. B Route the neutral switch lead direct to upper right side. 1 2 3 4 SPEC D Route the EXUP cables behind the swing arm head pipe.

CABLE ROUTING 1 2 3 4 5 6 7 8 9 10 11 12 SPEC Headlight sub-wire harness Left handlebar switch lead Main switch lead Starter cable Right handlebar switch coupler Throttle cables Engine air vent hose EXUP servomotor coupler Air vent surge tank Starter motor lead Pickup coil coupler Fuel pump coupler 13 14 15 16 17 18 19 20 21 22 23 24 Neutral switch connector Battery negative lead Rear brake switch coupler Speed sensor coupler EXUP cable Fuel tank overflow hose Fuel tank breather hose (except for California) Tail light lead Rear flasher light lead Crankcase breather hose Generator coupler Sidestand switch coupler –27– .

CABLE ROUTING 25 26 27 28 29 30 31 32 33 34 35 SPEC Engine oil level switch lead Air filter case drain hose Air induction system hose Ignition coil Cover Rivet Screw Coupler Main harness Frame Rear fender –28– .

rear brake light lead. I Fasten the wire harness and ignition coil subwire harness with a plastic clamp. B Route the horn lead over the horn bracket and make sure that the lead has no slack. C Do not cross the throttle cables and right handlebar switch lead. SPEC G To the carburetor.CABLE ROUTING A Make sure the headlight lead in the rubber cover. K Fasten the fuel pump lead. starter motor lead and EXUP cable with a plastic clamp. E Fasten the main harness and thermo switch lead with a plastic clamp. fuel sender lead. speed sensor lead. D Route the thermo switch lead through the steel band on the radiator. F Route the ignition coil sub-wire harness under the throttle position sensor. neutral switch lead. Insert the plastic clamp into the hole on the frame. J Route the idle adjust cable upper the ground lead. –29– . H Route the coolant reservoir tank breather hose upper the air vent surge tank.

95 in) rear fender. rear brake light lead. fuel send.17 in) er lead. V Insert the tail / brake light lead and turn signal leads P To the fuel sender. M 125 mm (4.S 30 mm (1. Route the rear flasher light R Insert the fuel tank breather hose into a back side lead and taillight lead in the hole on the taillight nipple of fuel tank. –30– . O To the fuel cock. tank breather hose have each white mark. speed sensor lead. with a plastic clamp. The fuel tank nipple and the fuel bracket.88 in) U Route the rear flasher light lead in the hole on the N 50 mm (1.CABLE ROUTING SPEC L Fasten the fuel pump lead. Q Insert the fuel tank over flow hose into a front side W Fasten the rear flasher light lead and taillight lead nipple of fuel tank. under the tail / brake light. neutral switch lead. starter motor lead and EXUP cable with a T Fasten the battery positive lead and starter motor plastic clamp. lead with a plastic locking tie.

engine oil level sensor coupler. H’ Make sure the sidestand switch coupler. F’ To the idle adjust screw. C’ Fasten the main harness. starting circuit cutoff relay lead. battery negative lead and rear fender with a plastic clamp. Z Route the ground lead under the starter relay lead.CABLE ROUTING X Fasten the main harness with a plastic band on the rear fender. Route the clamp end to outside. B’ Route the taillight leads through the rear fender. G’ To the engine backward. battery negative lead is fixed to wire harness. EXUP servo motor coupler and acmagneto coupler in the rubber cover. and insert it between wire harness and fender. alam lead and main harness with a plastic clamp. Clamp the battery negative lead with a white tape mark. ground lead. Y Position the ground coupler over the main harness. E’ Route the fuel tank overflow hose and fuel tank breather hose in front of the crank case breather hose and under the fuel hose and front of the EXUP servomotor bracket and upper the EXUP servomotor. SPEC D’ At the back side of turning point. A’ Fasten the starter relay lead. –31– .

Insert the plastic clamp into the hole on the frame. and the latter. (California only) K’ Fasten the wire harness with a plastic clamp and then insert the clamp into the frame. Connect the couplers of the same color. Fasten the main harness and fan motor lead with a plastic clamp. The clamp position SPEC should be not exceed just behind 30 mm of all coupler. O’ 0 X 30 mm P’ Although the main switch lead couplers and the handlebar switch lead couplers are the same in shape. –32– . Q’ Direct the ignition coil leads upward and insert them into position at the rubber damper. N’ Route the band end to inside. coolant reservoir tank breather hose and all of leads. J’ Route the charcoal canister hose under the engine air vent hose. T’ Route the battery positive lead upper the main harness. M’ Route the main harness and fan motor lead into the hole on the air intake guide. blue). R’ 90_ S’ Route the battery negative lead inside the main harness. they differ in color (the former is white. L’ To the radiator fan motor.CABLE ROUTING I’ Fasten the main harness with a plastic clamp.

000 km After the first 1. S Check balance. S Adjust if necessary.000 km and after washing the motorcycle or riding in the rain 13 * Swingarm 14 Drive chain 15 * Steering bearings –33– . S Check bearing play and Steering for roughness. All service technicians should be familiar with this entire chapter. S Check valve clearance. S Clean or replace if necessary. S Correct accordingly. S Correct accordingly. Make sure that the rear wheel is properly aligned. Replace if necessary. S Replace if necessary. S Lubricate with lithium soap base grease. This information applies to vehicles already in service as well as to new vehicles that are being prepared for sale. S Replace brake pads if necessary. S Replace if necessary. S Rebalance or replace if necessary. these preventive maintenance procedures will ensure more reliable vehicle operation. S Correct if necessary. runout and for damage.PERIODIC MAINTENANCE AND LUBRICATION INTERVALS EB300000 CHK ADJ PERIODIC CHECKS AND ADJUSTMENTS INTRODUCTION This chapter includes all information necessary to perform recommended checks and adjustments. S Check condition. S Clean. S Adjust or replace cable. If followed. S Clean and lubricate. regap or replace if necessary. S Replace if necessary. S Replace if necessary. S Check operation. Correct if necessary. EB301000 PERIODIC MAINTENANCE AND LUBRICATION INTERVALS No. fluid level and vehicle for fluid leakage. a longer service life and reduce the need for costly overhaul work. S Correct accordingly. S Lubricate with lithium soap base grease. S Check operation. Check air pressure. S Check condition. S Adjust if necessary. fluid level and vehicle for fluid leakage. S Check for cracks or damage. S S S S Check tread depth and for damage. S Check swingarm pivoting point for play.000 km Every 10.000 km Every 20. No ITEM CHECKS AND MAINTENANCE JOBS S Check fuel hoses and vacuum hose for cracks or damage. Every 40. S Check chain slack.000 km Every 1. S Replace brake pads if necessary. S Check operation. Every 24.000 km Annual check 1 * Fuel line 2 3 4 5 6 * Fuel filter Spark plugs * Valves Air filter Clutch 7 * Front brake 8 * Rear brake 9 * Brake hose 10 * Wheels 11 * Tires 12 * Wheel bearings S Check bearing for looseness or damage.

S Correct accordingly. S Change coolant. bolts and screws are properly tightened. S Replace the brake hoses every four years and if cracked or damaged. S Check operation and shock absorber for oil leakage. S Check the air cut valve and reed valve for damage. S Check operation. S Tighten if necessary.PERIODIC MAINTENANCE AND LUBRICATION INTERVALS No. S Lubricate if necessary. (Warm engine before draining.000 km Annual check 16 * Chassis fasteners Sidestand Sidestand switch 17 18 * 19 * Front fork Rear shock 20 * absorber assembly Rear suspension 21 * relay arm and connecting arm pivoting points 22 * Carburetors S Check operation.) S Replace. have a Yamaha dealer perform the service. S Every two years replace the internal components of the brake master cylinder and caliper. S Check coolant level and vehicle for coolant leakage. synchronization and starter operation. S Check the screw clamp for looseness. S Check operation. S Replace the entire air induction system if necessary. S Correct if necessary.000 km Every 10. S Correct if necessary.000 km maintenance was performed in the same year. –34– . S Correct if necessary.000 km or 20. S Correct if necessary. NOTE: D The annual checks must be performed once a year unless a 10. S Check operation. S Correct accordingly. and change the brake fluid. S Replace shock absorber assembly if necessary. D Hydraulic brake service S Regularly check and. correct the brake fluid level. 23 Engine oil Engine oil filter cartridge Cooling system Cooling system 24 25 * Front and rear 26 * brake switches 27 28 * 29 * Moving parts and cables Air induction system Exhaust system Lights. S Check operation and for oil leakage. signals and switches 30 * * Since these items require special tools. S Check oil level and vehicle for oil leakage. D The air filter needs more frequent service if you are riding in unusually wet or dusty areas. if necessary. S Adjust headlight beam if necessary. S Tighten if necessary. S Check engine idling speed. S Adjust if necessary. S Replace if necessary. S Lubricate and repair if necessary. No ITEM CHECKS AND MAINTENANCE JOBS S Make sure that all nuts.000 km CHK ADJ Every 20. data and technical skills. S Check operation. S Change. After the first 1.

1 2 3 4 5 6 7 8 9 1 1 1 1 1 1 1 2 1 Front installation. –35– .COWLINGS EB302020 CHK ADJ COWLINGS 5 Nm (0.5 mSkg) Order Job/Part Removing the cowlings Rider and passenger seats Rear cowling Bottom cowling Front cowling inner panel (left) Front cowling inner panel (right) Left side cowling Right side cowling Windshield Rear view mirror Front cowling Q’ty Remarks Remove the parts in the order listed. Refer to “SEATS”. reverse the removal procedure.

For installation. 1 2 3 4 5 6 7 8 9 10 11 1 1 1 4 1 1 2 1 4 1/2 1 Loosen. Disconnect. Refer to “SEATS” and “FUEL TANK”.AIR FILTER CASE AND IGNITION COIL PLATE EB302040 CHK ADJ AIR FILTER CASE AND IGNITION COIL PLATE Order Job/Part Removing the air filter case and ignition coil plate Rider seat and fuel tank Crankcase breather hose Air filter case breather hose Air induction system hose Clamp screw Bolt Air filter case Quick fastener Ignition coil coupler Spark plug cap Ignition coil plate/ignition coil Rubber baffle Q’ty Remarks Remove the parts in the order listed. –36– . reverse the removal procedure.

reverse the removal procedure.ENGINE CHK ADJ OVERHAULING THE ENGINE AIR INDUCTION SYSTEM 4 Nm (0.4 mSkg) Order 1 2 3 4 Job/Part Removing the air induction system Air induction pipe Air cutoff valve Carburetor joint hose Air intake hose Q’ty 4 1 1 1 Remarks Remove the parts in the order listed. For installation. –37– .

4 mSkg) 40 Nm (4. –38– .ENGINE ENG ENGINE 24 Nm (2.0 mSkg) 55 Nm (5.4 mSkg) 55 Nm (5. reverse the removal procedure.5 mSkg) 40 Nm (4. For installation.5 mSkg) 24 Nm (2. 1 2 3 4 5 6 7 8 9 Pinch bolt Right front mounting bolt Washer Spacer Left front mounting bolt Washer Self-locking nut Rear mounting bolt Spacer 2 1 1 1 2 2 2 2 1 Loosen.4 mSkg) Order Job/Part Removing the engine Q’ty Remarks Remove the parts in the order listed. NOTE: Place a suitable stand under the frame and engine.

g. Install the spacer 1 to the frame. Temporally tighten the right front mounting bolt 2 . Self locking nut 8 9 55 Nm (5. Tighten the left mounting bolt 3 . Tighten the pinch bolt 10 . i. Lubricate the rear mounting bolts 6 7 threads with lithium soap base grease. e.5 mSkg) Right front mounting bolt 2 40 Nm (4.4 mSkg) –39– . Tighten the pinch bolt 11 .ENGINE EB400700 ENG INSTALLING THE ENGINE 1. d. and washers 4 5 . c.0 mSkg) Pinch bolts 10 11 24 Nm (2.0 mSkg) Left front mounting bolt 3 40 Nm (4. Tighten the self locking nut 8 . h. Install: S engine assembly a. f. b. Tighten the right mouthing bolt 2 . Install the rear mounting bolts 6 7 and self locking nut 8 9 . left front mounting bolt 3 . and then tighten the self locking nut 9 .

2 mSkg) Order Job/Part Removing the cylinder head Engine Intake and exhaust camshafts Cylinder head Cylinder head gasket Dowel pin Q’ty Remarks Remove the parts in the order listed.5 mSkg) 12 Nm (1.0 mSkg) 65 Nm (6.CYLINDER HEAD EB402000 ENG CYLINDER HEAD 50 Nm (5. Refer to “ENGINE”. Refer to “CAMSHAFTS”. reverse the removal procedure. –40– . 1 2 3 1 1 2 For installation.

Refer to “ENGINE”. Refer to “GENERATOR”. Refer to “OIL PAN AND OIL PUMP”. Refer to “CYLINDER HEAD”. Refer to “PICKUP COIL”.0 mSkg) Order Job/Part Separating the crankcase Engine Cylinder head Pickup coil and pickup coil rotor Stator coil assembly Clutch housing and starter clutch idle gear Oil/water pump assembly Timing chain Crankshaft sprocket Pin Oil/water pump assembly drive chain guide Oil/water pump assembly drive chain Q’ty Remarks Remove the parts in the order listed.CRANKCASE CRANKCASE ENG 10 Nm (1.0 mSkg) 10 Nm (1. 1 2 3 4 5 1 1 1 1 1 –41– . Refer to “CLUTCH”.

–42– .CRANKCASE ENG 10 Nm (1. reverse the removal procedure.0 mSkg) 10 Nm (1.0 mSkg) Order 6 7 8 9 10 Job/Part Oil/water pump assembly drive sprocket Washer Plate Lower crankcase Dowel pin Q’ty 1 1 1 1 3 Remarks For installation.

Install: S crankshaft journal lower bearings (into the lower crankcase) NOTE: S Align the projections a on the crankshaft journal lower bearings with the notches b in the lower crankcase. 5. 3. Do not apply sealant to within 2 X 3 mm of the crankshaft journal bearings. Set the shift drum assembly and transmission gears in the neutral position.CRANKCASE EB412743 ENG ASSEMBLING THE CRANKCASE 1. S Install each crankshaft journal lower bearing in its original place. –43– . Apply: S sealant (onto the crankcase mating surfaces and the groove a of the oil baffle plate) Yamaha bond No. Install: S dowel pin 4. 1215 90890-85505 NOTE: Do not allow any sealant to come into contact with the oil gallery or crankshaft journal bearings. Lubricate: S crankshaft journal bearings (with the recommended lubricant) Recommended lubricant Engine oil 2.

Install: S crankcase bolts NOTE: S Lubricate the bolt threads with engine oil. 25 65 mm bolt: 27 64 mm bolts: 16 .2 mSkg) Bolt 16 . S Tighten each bolt at 15 Nm in the tightening sequence cast on the crankcase.4 mSkg) Bolt 21 . S Install a washer on bolts 1 X 10 . 23 .4 mSkg) –44– . S Tighten bolts 11 to 28 as shown below. M9 M8 M8 M6 M6 M6 M6 M6 M6 M6 115 mm bolts: 1 X 10 60 mm bolt: 21 50 mm bolt: 22 70 mm bolts: 17 . 25 X 28 12 Nm (1. 17 X 20 . 24 60 mm bolt: 23 55 mm bolts: 11 X 15 50 mm bolt: 18 45 mm bolts: 20 . 22 24 Nm (2. 24 14 Nm (1.5 mSkg) + 45_ X 50_ Bolt 11 X 15 . 28 Bolt 1 X 10 15 Nm (1.CRANKCASE ENG 6. Install: S lower crankcase 1 (onto the upper crankcase 2 ) CAUTION: Before tightening the crankcase bolts. 7. S Loosen each bolt one time and tighten 15 Nm in the same sequence. S Tighten bolts 1 to 10 45_ X 50_ more. 19 . make sure that the transmission gears shift correctly when the shift drum assembly is turned by hand. 26 .

45 mSkg) Order Job/Part Removing the radiator Rider seat and fuel tank Air filter case and rubber cover Bottom cowling and side cowlings Drive sprocket cover Coolant Q’ty Remarks Remove the parts in the order listed.0 mSkg) 9 Nm (0.9 mSkg) 23 Nm (2. Refer to “CHANGING THE COOLANT” in chapter 3. Refer to “COWLINGS” in chapter 3. Refer to “ENGINE” in chapter 4. Refer to “AIR FILTER CASE AND IGNITION COIL PLATE” in chapter 3. Refer to “SEATS” and “FUEL TANK” in chapter 3.RADIATOR EB500000 COOL COOLING SYSTEM RADIATOR 10 Nm (1. –45– . Drain. 1 2 3 4 Coolant reservoir breather hose Coolant reservoir hose Coolant reservoir Thermo unit coupler 1 1 1 1 Disconnect.3 mSkg) 4.0 mSkg) 20 Nm (2.5 Nm (0.

0 mSkg) 9 Nm (0.3 mSkg) 4.RADIATOR COOL 10 Nm (1. reverse the removal procedure.45 mSkg) Order 5 6 7 8 9 10 11 12 13 14 15 Job/Part Thermo unit Thermostat assembly breather hose Radiator inlet hose Oil cooler outlet hose Water pump breather hose Radiator outlet hose Water pump inlet pipe Radiator fan motor coupler Horn bracket Radiator Radiator fan Q’ty 1 1 1 1 1 1 1 1 1 1 1 Disconnect.5 Nm (0.9 mSkg) 23 Nm (2. Disconnect. For installation. Remarks Disconnect.0 mSkg) 20 Nm (2. –46– .

the valve will close. the air cutoff valve is open to allow fresh air to flow into the exhaust port. reducing the emission of hydrocarbons. negative pressure is generated and the air cutoff valve is closed in order to prevent after-burning. the air cutoff valve automatically closes to guard against a loss of performance due to self-EGR.) VIEW 1. (FLOW) –47– . (FLOW) During normal operation the valve is open. A From the air filter B To the reed valve C To the carburetor joint VIEW 2. (NO FLOW) AIR CUTOFF VALVE The air cutoff valve is operated by the intake gas pressure through the piston valve diaphragm. Normally. During sudden deceleration (the throttle valve suddenly closes).AIR INDUCTION SYSTEM EAS00507 CARB CARBURETORS AIR INDUCTION SYSTEM AIR INJECTION The air induction system burns unburned exhaust gases by injecting fresh air (secondary air) into the exhaust port. the reed valve opens. at high engine speeds and when the pressure decreases. When there is negative pressure at the exhaust port. EAS00508 VIEW 1. The required temperature for burning the unburned exhaust gases is approximately 600 to 700_C. allowing secondary air to flow into the exhaust port. (NO FLOW) When decelerating (the throttle closes). Additionally. VIEW 2. (This “low-boost close” function is the same as on the FZR600 (3HW).

AIR INDUCTION SYSTEM EAS00509 CARB AIR INDUCTION SYSTEM DIAGRAMS 1 2 3 4 Reed valve Air cleaner Air cutoff valve Carburetor joint (cylinder #1) A B D D E To the air cutoff valve To cylinder #1 To cylinder #2 To cylinder #3 To cylinder #4 –48– .

Cracks/damage ! Replace. Check: S hoses Loose connection ! Connect properly. Check: S fibre reed 1 S fibre reed stopper S reed valve seat S Cracks/damage ! Replace. Fibre reed bending limit 0. Check: S air cutoff valve Cracks/damage ! Replace. S pipes Cracks/damage ! Replace.AIR INDUCTION SYSTEM EAS00510 CARB CHECKING THE AIR INDUCTION SYSTEM 1. –49– . Measure: S fibre reed bending limit a Out of specification ! Replace the reed valve. 2.4 mm 1 Surface plate 4. 3.

NOTE: Place the motorcycle on a suitable stand so that the front wheel is elevated. 1 2 3 4 5 6 7 8 Brake hose holder (left and right) Brake caliper (left and right) Wheel axle pinch bolt Front wheel axle Front wheel Collar (left and right) Oil seal cover (left and right) Brake disc (left and right) 2 2 1 1 1 2 2 2 Loosen. reverse the removal procedure.6 mSkg) 72 Nm (7. –50– .0 mSkg) 18 Nm (1.2 mSkg) 40 Nm (4.8 mSkg) Order Job/Part Removing the front wheel and brake discs Q’ty Remarks Remove the parts in the order listed. For installation. Refer to “INSTALLING THE FRONT WHEEL”.FRONT WHEEL AND BRAKE DISCS EB700002 CHAS CHASSIS FRONT WHEEL AND BRAKE DISCS 6 Nm (0.

make sure that wheel axle 1 top end side and front fork end side are align a together.8 mSkg) NOTE: S Apply LOCTITE® 648 to the threads of the brake disc bolts. Tighten: S wheel axle 1 S wheel axle pinch bolt 1 72 Nm (7. 3. CAUTION: Before tightening the wheel axle nut. –51– . Install: S brake discs 1 18 Nm (1. push down hard on the handlebars several times and check if the front fork rebounds smoothly. Lubricate: S wheel axle S oil seal lips Recommended lubricant Lithium soap base grease 2.0 mSkg) WARNING Make sure that the brake hose is routed properly. tighten wheel axle pinch bolt 2 . Install: S brake calipers 40 Nm (4.2 mSkg) 23 Nm (2.FRONT WHEEL AND BRAKE DISCS EB700725 CHAS INSTALLING THE FRONT WHEEL 1. S Tighten the brake disc bolts in stages and in a crisscross pattern.3 mSkg) NOTE: When front wheel is installed to front fork. Then. 4.

0 mSkg) 23 Nm (2.5 mSkg) 30 Nm (3.FRONT AND REAR BRAKES EB702202 CHAS FRONT AND REAR BRAKES REAR BRAKE MASTER CYLINDER AND BRAKE FLUID RESERVOIR 5 Nm (0. 1 2 3 4 5 6 7 8 9 10 1 1 1 1 1 1 1 2 1 1 For installation.3 mSkg) Order Job/Part Removing the rear brake master cylinder and brake fluid reservoir Brake fluid Brake fluid reservoir cap Brake fluid reservoir diaphragm holder Brake fluid reservoir diaphragm Brake fluid reservoir Brake fluid reservoir hose Hose joint Union bolt Copper washer Brake hose Brake master cylinder Q’ty Remarks Remove the parts in the order listed. reverse the removal procedure. –52– . Drain.

The electrical circuit of the warning light can be checked according to the following procedure. Push the start switch. Refer to “SELF-DIAGNOSIS”. but this is not a malfunction. Oil level warning light “ ” This warning light comes on when the engine oil level is low. 1 2 3 4 5 Neutral indicator light “ ” High beam indicator light “ ” Turn signal indicator light “ ” Fuel level warning light “ ” Oil level warning light “ ” Fuel level warning light “ ” This warning light comes on when the fuel level drops below approximately 3.8 L. –53– . 1. Turn signal indicator light “ ” This indicator light flashes when the turn signal switch is pushed to the left or right. Set the engine stop switch to “ ” and turn the key to “ON”. If the warning light does not come on while pushing the start switch. NOTE: This model is equipped with a selfdiagnosis device for the fuel level warning light circuit. When this occurs. refuel as soon as possible. Push the start switch. 1. Set the engine stop switch to “ ” and turn the key to “ON”. 2. The electrical circuit of the warning light can be checked according to the following procedure.INSTRUMENT FUNCTIONS ELEC ELECTRICAL INSTRUMENT FUNCTIONS INDICATOR LIGHTS Neutral indicator light “ ” This indicator light comes on when the transmission is in the neutral position. the warning light may flicker when riding on a slope or during sudden acceleration or deceleration. Shift the transmission into the neutral position or pull the clutch lever. 3. have a Yamaha dealer check the electrical circuit. NOTE: Even if the oil level is sufficient. ” High beam indicator light “ This indicator comes on when the headlight high beam is used. 2. If the warning light does not come on while pushing the start switch. 3. have a Yamaha dealer check the electrical circuit. Shift the transmission into the neutral position or pull the clutch lever.

Push the start switch. Go ahead with riding. Warning light comes on. Go ahead with riding. Warning light comes on. have a Yamaha dealer check the electrical circuit.INSTRUMENT FUNCTIONS COOLANT TEMPERATURE WARNING LIGHT ELEC 1 Coolant temperature gauge 2 Coolant temperature warning light “ ” Coolant temperature warning light “ ” This warning light comes on when the engine overheats. CAUTION: Do not operate the engine if it is overheated. Refer to “OVER HEATING” in chapter 9. Coolant temperature Display Conditions What to do 0 – 39_C Message “LO” is displayed. Stop the motorcycle and allow it to idle until the coolant temperature goes down. When this occurs. 117 – 139_C Temperature flashes. If the warning light does not come on while pushing the start switch. 3. Set the engine stop switch to “ ” and turn the key to “ON”. stop the engine immediately and allow the engine to cool. Above 140_C Message “HI” flashes. 2. Refer to “OVER HEATING” in chapter 9. 40 – 116_C Temperature is displayed. –54– . Shift the transmission into the neutral position or pull the clutch lever. The electrical circuit of the warning light can be checked according to the following procedure. OK. If the temperature does not go down. OK. Stop the engine and allow it to cool. stop the engine. 1.

select it by pushing the “SELECT” button. the display automatically returns to the prior mode. NOTE: After resetting the fuel reserve tripmeter. the display will return to “TRIP 1”. in that case. it will reset itself automatically and the display will return to “TRIP 1” after refueling and traveling 5 km.INSTRUMENT FUNCTIONS SPEEDOMETER UNIT ELEC 1 Speedometer 2 Odometer / tripmeter / fuel reserve tripmeter / clock 3 “RESET” button 4 “SELECT” button The speedometer unit is equipped with the following: S a digital speedometer (which shows riding speed) S an odometer (which shows the total distance traveled) S two tripmeters (which show the distance traveled since they were last set to zero) S a fuel reserve tripmeter (which shows the distance traveled on the fuel reserve) S a clock Odometer and tripmeter modes Pushing the “SELECT” button switches the display between the odometer mode “ODO” and the tripmeter modes “TRIP 1” and “TRIP 2” in the following order: ODO ! TRIP 1 ! TRIP 2 ! ODO If the fuel level warning light comes on (see page 3-2). If you do not reset the fuel reserve tripmeter manually. pushing the “SELECT” button switches the display between the various tripmeter and odometer modes in the following order: TRIP F ! TRIP 1 ! TRIP 2 ! ODO ! TRIP F To reset a tripmeter. unless a different mode had been previously selected. –55– . In that case. and then push the “RESET” button. the odometer display will automatically change to the fuel reserve tripmeter mode “TRIP F” and start counting the distance traveled from that point.

When the hour digits start flashing. push the “RESET” button to set the hours. push the “SELECT” button. To change the display back to the odometer modes. Tachometer The electric tachometer allows the rider to monitor the engine speed and keep it within the ideal power range. CAUTION: Do not operate the engine in the tachometer red zone. the tachometer will repeatedly display the following error code: 0 r / min for 3 seconds Circuit-specific number of r / min for 2. Push the “RESET” button to set the minutes. and the minute digits will start flashing.750 r/min and above Self-diagnosis devices This model is equipped with a self-diagnosis device for the following electrical circuits: S Throttle position sensor S Speed sensor S EXUP system If any of those circuits are defective.5 seconds (See the table below. Push the “SELECT” button and then release it to start the clock. 4. push the “SELECT” button for at least one second. To set the clock: 1. 2. Red zone: 11. Push the “SELECT” button and “RESET” button together for at least two seconds. Push the “SELECT” button. 3.INSTRUMENT FUNCTIONS ELEC Clock mode To change the display to the clock mode.) Current engine speed for 3 seconds –56– . 5.

reverse the removal procedure. Refer to “COWLINGS” in chapter 3.ELECTRIC STARTING SYSTEM ELECTRIC STARTING SYSTEM STARTER MOTOR 5 Nm (0. –57– . 1 2 3 4 1 1 1 1 For installation.7 mSkg) ELEC Order Job/Part Removing the starter motor Rider seat Fuel tank Left side cowling EXUP servomotor Throttle stop screw Starter motor lead Starter motor assembly Q’ty Remarks Remove the parts in the order listed. Refer to “SEATS” in chapter 3. Refer to “FUEL TANK” in chapter 3.5 mSkg) 7 Nm (0.

5 mSkg) Order 1 2 3 4 5 6 7 8 9 Job/Part Disassembling the starter motor Starter motor rear cover Bearing Starter motor yoke O-ring Armature assembly Brush Brush holder Starter motor front cover Bearing Q’ty 1 1 1 2 1 2 1 1 1 Remarks Disassembly the parts in the order listed. reverse the disassembly procedure –58– .ELECTRIC STARTING SYSTEM EB803501 ELEC 5 Nm (0. For assembly.

Measure: S commutator diameter a Out of specification ! Replace the starter motor.5 mm NOTE: The mica must be undercut to ensure proper operation of the commutator. Mica undercut 1. 2. Pocket tester 90890-03112 Armature assembly Commutator resistance 1 Continuity OK NO continuity NG Insulation resistance 2 Above 1 MΩ at 20_C b. replace the starter motor. Check: S commutator Dirt ! Clean with 600 grit sandpaper. Measure the armature assembly resistances with the pocket tester. 4.5 mm 3. a. –59– . Measure: S armature assembly resistances (commutator and insulation) Out of specification ! Replace the starter motor.ELECTRIC STARTING SYSTEM EB803511 ELEC Checking The Starter Motor 1. If any resistance is out of specification. Min. Measure: S mica undercut a Out of specification ! Scrape the mica to the proper measurement with a hacksaw blade which has been grounded to fit the commutator. commutator diameter 23.

EB803701 Assembling The Starter Motor 1. Measure: S brush length a Out of specification ! Replace the brushes as a set. Brush spring force 5.28 X 7. 8. Measure: S brush spring force Out of specification ! Replace the brush springs as a set. 2. Check: S gear teeth Damage/wear ! Replace the gear. brush length 3. Check: S bearing S oil seal Damage/wear ! Replace the defective part(-s). Install: S armature 1 –60– . Install: S brush seat 1 NOTE: Align the tab a on the brush seat with the slot b in the starter motor front cover.65 mm 6.92 N 7. Min.ELECTRIC STARTING SYSTEM ELEC 5.

Install: S starter motor yoke 2 S O-rings 1 New S starter motor rear cover 3 S bolts 5 Nm (0. –61– .5 mSkg) NOTE: Align the match marks a on the starter motor yoke with the match marks b on the front and rear covers.ELECTRIC STARTING SYSTEM ELEC 3.

COOLING SYSTEM EB807000 ELEC COOLING SYSTEM CIRCUIT DIAGRAM 1 5 6 22 28 48 49 50 Main switch Battery Main fuse Thermo unit Combination meter Radiator fan motor Radiator fan motor relay Radiator fan motor fuse –62– .

battery 3. S Connect the battery (12 V) as shown. Radiator fan motor S Disconnect the radiator fan motor coupler from the wire harness. signal system. however. 1) rider seat 2) bottom cowling 3) front cowling inner panels 4) left side cowling 5) windshield S Troubleshooting with the following special tool(-s). Open-circuit voltage 12. is not trouble. main switch 4. Refer to “CHECKING THE FUSES” in chapter 3. S Are the main. Fan motor relay 6. Refer to “CHECKING AND CHARGING THE BATTERY” in chapter 3. main. S Recharge or replace the battery. S Is the main switch OK? YES Replace switch. the radiator fan motor will start rotating. signal system. even when the coolant temperature is low enough. Pocket tester 90890-03112 EB802400 3. and radiator fan motor fuses OK? YES NO Replace the fuse(-s). Main. 2.COOLING SYSTEM EB807010 EB802401 ELEC TROUBLESHOOTING S The radiator fan motor fails to turn. Thermo unit 8.500 rpm for at least one minute with the switch remaining placed in neutral position and the throttle valve fully open.8 V or more at 20_C S Is the battery OK? YES NO S Clean the battery terminals. Wiring (the entire cooling system) NOTE: S Before troubleshooting. radiator fan motor 5. S Keep hands and other body regions away to avoid injury. and radiator fan motor fuses for continuity. Refer to “CHECKING THE SWITCHES”. This. remove the following part(-s). EB807400 NO the main 4. Check: 1. S The coolant temperature meter needle fails to move when the engine is warm. Main switch S Check the main switch for continuity. signal system. S Does the radiator fan motor turn? YES NO –63– . Battery S Check the condition of the battery. Battery positive lead ! blue 1 Battery negative lead ! black 2 1. and radiator fan motor fuses 2. Speedometer 7. signal system and radiator fan motor fuses S Check the main. EB802411 CAUTION: S If the engine is kept running at over 1. The radiator fan motor is faulty and must be replaced.

S Handle the thermo unit with special care.6 X 1. If the thermo unit is dropped. S Set the main switch to “ON”.3 mSkg) Three bond sealock® 10 –64– .0 kΩ at 80_C 1. S Connect the pocket tester (Ω 1) and battery (12V) to the fan motor relay coupler as shown. S Slowly heat the coolant. S Check the thermo unit for continuity at the temperatures indicated in the table.4 kΩ at 50_C 3. Fan motor relay S Disconnect the fan motor relay coupler.COOLING SYSTEM EB807400 EB807402 ELEC 5. NOTE: Make sure that the thermo unit terminals do not get wet. S Connect the green/red 1 and black/blue 2 terminals with a jumper lead 3 as shown. Thermo unit 9.1 X 1. S Immerse the thermo unit in a container filled with coolant 2 . EB807400 6.2 kΩ at 120_C S Does the radiator fan motor relay have continuity between brown and blue? YES NO Replace the fan motor relay. then let it cool to the specified temperature as indicated in the table. S Place a thermometer 3 in the coolant. Thermo unit S Remove the thermo unit from the radiator. Thermo unit 23 Nm (2. S Never subject the thermo unit to strong shocks. S Connect the pocket tester (Ω 1) to the thermo unit 1 as shown.7 X 11. replace it.9 kΩ at 105_C 1. WARNING S Does the coolant temperature display “HI” and warning light comes on? YES NO The speedometer is faulty and must be repaired.4 X 4. Speedometer S Disconnect the thermo unit coupler. Battery positive lead ! brown 1 Battery negative lead ! green/black 2 Tester positive prove ! brown 3 Tester negative prove ! blue 4 7.

COOLING SYSTEM
S Does the thermo unit operate properly as described above? YES NO Replace the thermo unit.
EB807403

ELEC

8. Wiring S Check the entire cooling system’s wiring. Refer to “CIRCUIT DIAGRAM”. S Is the cooling system’s wiring properly connected and without defects? YES This circuit is OK. NO Properly connect or repair the cooling system’s wiring.

–65–

SELF-DIAGNOSIS
EB812000

ELEC

SELF-DIAGNOSIS
The YZF-R1 features a self-diagnosing system for the following circuit(-s): S throttle position sensor S EXUP S speed sensor S fuel level warning light If any of these circuits are defective, their respective condition codes will be displayed on the tachometer when the main switch is set to “ON” (irrespective of whether the engine is running or not) Circuit Throttle position sensor Defect(-s) S Disconnected S Short-circuit S Locked S Improper connection S Short-circuit System response S The ignitor unit stays set to the wide-open throttle ignition timing. The motorcycle can be ridden. S The tachometer displays the condition code. S The EXUP valve stays in the open position for three seconds and then the servomotor shuts off. The motorcycle can be ridden. S The tachometer displays the condition code. S The servomotor’s power supply is constantly interrupted so that it will not burn out. The motorcycle can be ridden. S The tachometer displays the condition code. S The tachometer displays the condition code. S Display the condition code on the fuel level warning light. Condition code 3,000 r/min

EXUP

7,000 r/min

S Servomotor is locked.

Speed sensor Fuel level warning light

S Disconnected S Short-circuit S Improper connection S Short-circuit

4000 r/min The warning light will flash eight times, then go off for three seconds.

Tachometer display sequence
1 0 r / min ... 3 seconds 2 Condition code ... 2.5 seconds 3 Engine speed ... 3 seconds

Revolution ( 103 r / min)

Tachometer display

Engine speed

Time (seconds)

When more than one item is being monitored, the tachometer needle displays the condition codes in ascending order, cycling through the sequence repeatedly. If the engine is stopped, the engine speed 3 is 0 r/min.

–66–

SELF-DIAGNOSIS
EB812010

ELEC

TROUBLESHOOTING The tachometer starts to display the selfdiagnosis sequence. Check: 1. speed sensor 2. fuel level warning light NOTE: S Troubleshoot tool(-s). with the following special

2. Speed sensor S Place the motorcycle on a suitable stand so that the rear wheel is elecated. S Connect the pocket tester (DC 20V) to the speed sensor connector. Tester (+) lead ³ White 1 terminal Tester (–) lead ³ Body earth

Pocket tester 90890-03112 1. Speed sensor CIRCUIT DIAGRAM

S Set the main switch to “ON”. S Turn the rear wheel slowly. S Check the tester voltage (0V - 5V - 0V). S Is the speed sensor OK? YES Replace the ignitor unit. NO Replace the speed sensor.

2. Fuel level warning light (Refer to signal system)

16 Ignitor unit 21 Speed sensor

1. Wire harness S Check the wire harness for continuity. Refer to “CIRCUIT DIAGRAM”. S Is the wire harness OK? YES NO Repair or replace the wire harness.

–67–

.

. . R. . black brown chocolate dark green green gray blue orange pink red Sb . . .. . Y/ B . . .... ... R/ W .. B/ L . . R/ B . . ... Y .. P . .YZF-R1 WIRING DIAGRAM (For EUR) COLOR CODE B . red / blue red / white red / yellow white/ black white/ green white/ yellow yellow/ black yellow/ blue 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 Main switch Backup fuse (odometer) Rectifier/ regulator Generator Battery Main fuse Starter relay Starter motor Relay unit Starting circuit cutoff relay Fuel pump relay Fuel pump Sidestand switch EXUP servomotor Throttle position sensor Ignition unit Ignition coil Spark plug Pickup coil Neutral switch Speed sensor Thermo unit Meter assembly Fuel level indicator light Oil level warning light Neutral indicator light Tachometer Combination meter Coolant temperature meter High beam indicator light Turn signal indicator light Meter light Fuel sender Left handlebar switch Pass switch Dimmer switch Horn switch Horn Clutch switch Turn signal switch Turn signal relay Rear turn signal light Front turn signal light Headlight Auxiliary light Headlight relay Tail/ brake light Radiator fan motor Radiator fan motor relay Radiator fan motor fuse Headlight fuse Signaling system fuse CYCLELOCK (option) Ignition fuse Engine oil level switch Rear brake light switch Right handlebar switch Front brake light switch Lights switch Engine stop switch Start switch . L/R .. . B/ R . . . Br/ R . . . G/W .. . . . . .. B/ Y .. Gy . . .. R/ G .. W/ Y .. . . .... L/Y .. . sky blue white yellow black/ blue black/ red black/ white black/ yellow brown/ blue brown/ red brown/ white G/R . W . R/ Y . O/R . . .. . W/ B .. . O . Br/ W . Dg . .. .. . Ch . L .. . . green / red green / white green / yellow blue/ black blue/ red blue/ white blue/ yellow orange / red red / black red / green R/ L . . L/B . Y/ L . . . . G . .. Br . G/Y . Br/ L . B/ W . L/W . . . . W/ G .. ..

. R/ G . . .. . B/ R . . .. R/ W .. O/R . Br/ R . ... . . R/ B .. . . .. L/B . O . red / blue red / white red / yellow white/ black white/ green white/ yellow yellow/ black yellow/ blue Main switch Backup fuse (odometer) Rectifier/ regulator Generator Battery Main fuse Starter relay Starter motor Relay unit Starting circuit cutoff relay Fuel pump relay Fuel pump Sidestand switch EXUP servomotor Throttle position sensor Ignition unit Ignition coil Spark plug Pickup coil Neutral switch Speed sensor Thermo unit Meter assembly Fuel level indicator light Oil level warning light Neutral indicator light Tachometer Combination meter Coolant temperature meter High beam indicator light Turn signal indicator light Meter light Left handlebar switch Pass switch Dimmer switch Horn switch Horn Clutch switch Turn signal switch Turn signal relay Fuel sender Rear turn signal light Front turn signal light Headlight Headlight relay Tail/ brake light Radiator fan motor Radiator fan motor relay Radiator fan motor fuse Headlight fuse Signaling system fuse Ignition fuse Engine oil level switch Rear brake light switch Right handlebar switch Front brake light switch Engine stop switch Start switch .. . B/ W .. Y/ L . . black brown chocolate dark green green gray blue orange pink red Sb . . . . Y . ..YZF-R1 WIRING DIAGRAM (For OCE) 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 COLOR CODE B . .. . . .. . G/W . . Br/ L . . . . L/W . Y/ B .. . Gy .. Ch . L .. . sky blue white yellow black/ blue black/ red black/ white black/ yellow brown/ blue brown/ red brown/ white G/R . . . .. B/ L . . W/ G . . R.... . . .. . W/ Y . . . .. B/ Y . .. Br . G . Br/ W . R/ Y . Dg .. W . .. P .. L/Y . L/R . W/ B . . . . . G/Y . green / red green / white green / yellow blue/ black blue/ red blue/ white blue/ yellow orange / red red / black red / green R/ L .. ...