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.

A NOTE provides key information to make procedures easier or clearer. 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. 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.EB001000 NOTICE This manual was produced by the Yamaha Motor Company. A CAUTION indicates special precautions that must be taken to avoid damage to the motorcycle. CAUTION: NOTE: . Repair and maintenance work attempted by anyone without this knowledge is likely to render the vehicle unsafe and unfit for use. is continually striving to improve all of its models. Ltd. 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. a bystander or a person checking or repairing the motorcycle. it is not possible to include all the knowledge of a mechanic in one manual. Therefore. NOTE: Designs and specifications are subject to change without notice. Yamaha Motor Company. EB002000 IMPORTANT MANUAL INFORMATION Particularly important information is distinguished in this manual by the following. primarily for use by Yamaha dealers and their qualified mechanics. Ltd.

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

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. 24 Apply locking agent (LOCTITE®) 25 Replace the part . Symbols 1 to 9 indicate the subject of each chapter. 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. 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. 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.

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

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

passenger. rider.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 3.095 mm (for AUS) 695 mm 1.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.035 mm 2.105 mm 815 mm 1.

100 r/min (0.8 : 1 1.000 X 1.9 X 5.100 r/min 29.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-stroke.7 kgf/cm2) SSS SSS SSS SSS SSS SSS –2– . SPEC Standard Liquid-cooled.9 L 45 kPa at 1.450 kPa (14.8 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 3.5 kgf/cm2) at 400 r/min SSS SSS SSS SSS SSS SSS SSS SSS Limit Regular unleaded gasoline Unleaded fuel (for AUS) 18 L 3.45 kgf/cm2 at 1.100 r/min) 490 X 570 kPa (4.3 kPa (220 mm Hg) 1. DOHC 998 cm3 Forward-inclined parallel 4-cylinder 74 58 mm 11.6 L 2.7 L 2.

65 mm 32.028 X 0.95 X 25.75 X 7.472 mm 0.85 mm SSS 0.521 mm 24.05 mm 24.500 X 24.05 mm 7.5 X 32.95 mm SSS 32.03 mm –3– .062 mm SPEC Limit SSS SSS SSS SSS Measurement A Measurement B Measurement C Exhaust camshaft lobe dimensions 32. camshaft runout 32.85 mm SSS Measurement A Measurement B Measurement C Max.95 X 33.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) 24.05 mm 7.459 X 24.45 X 7.4 mm 24.95 X 25.6 mm 24.85 mm 24.

1 mm 0.055 mm –1 = Violet 0 = White 1 = Blue 2 = Black SSS SSS SSS SSS –4– .6 mm 1.76 X 2.11 X 0.047 mm SSS SSS SSS SSS SSS SSS SSS SSS SSS 3.21 X 0.465 X 4.000 X 4.1 mm 0.9 X 1.08 mm 0.1 mm 0.512 mm 0.01 mm Valve seat width Intake Exhaust Connecting rods Crankshaft-pin-to-big-end-bearing clearance Bearing color code 0.5 X 0.20 mm 0.1 mm 24. valve seats.1 mm 0. valve guides Valve clearance (cold) Intake Exhaust Valve dimensions Standard SPEC Limit 0.05 mm 4.5 X 0.975 X 3.25 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 22.1 mm 0.90 mm 1.76 X 2.945 mm 4.037 mm 0.500 X 4.55 mm 0.ENGINE SPECIFICATIONS Item Valves.010 X 0.012 mm 4.9 mm 3.90 mm 0.020 X 0.43 mm 4.4 X 24.480 mm 4.031 X 0.9 X 1.990 mm 4.9 X 1.9 X 23.9 mm 0.9 X 1.

8 0.500) 28/21 (1.200) 29/26 (1.333) 30/25 (1.688) Left-foot operation 35/14 (2.0 #15 0.581) Chain drive 43/16 (2.08 mm 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.8 3. main axle runout Max.125 1.500) 35/19 (1.5 –5– .115) SSS SSS BDSR40 (MIKUNI) 3 X 5 mm 4 SPEC Limit SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS 0.842) 30/20 (1. 6-speed Spur gear 68/43 (1.08 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.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.9 0.

7 mm 38.1 mm 0. deflection Brake pad lining thickness Standard Tubeless 120/70 ZR17 (58W) MEZ3Y FRONT (METZELER) D207FQ (DUNLOP) 250 kPa (2. 2. thickness Max. 2.6 mm SSS SSS SSS SSS SSS 4. 2.9 bar) 250 kPa (2. 2.5 kg/cm2. 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. 2.5 bar) 250 kPa (2.5 mm 0.5 bar) 250 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.5 kg/cm2.5 bar) 290 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 mm Master cylinder inside diameter Caliper cylinder inside diameter 12.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.5 kg/cm2.9 kg/cm2.5 bar) SSS SPEC Limit SSS SSS SSS SSS SSS SSS 1. 2.6 mm Tubeless SSS 190/50 ZR17 (73W) SSS MEZ3Y (METZELER)/D207N (DUNLOP) SSS 250 kPa (2.2 mm SSS SSS –6– .5 kg/cm2.5 mm SSS SSS SSS 1.

with the inner tube fully compressed.35 N/mm (0.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.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– . 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 mm 7.

5 mm 78.200 kPa (12 kgf/cm2) 1 4 9 11 7 1 11 9 1 –8– .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 162.4 N/mm (7.84 kgf/mm) 0 X 65 mm No 1.

5 mm SSS SSS SSS SSS SSS SSS SSS SSS –9– .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 1.000 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 14.75 kW 9.32 N (488 X 732 gf) 0.65 mm SSS SSS 23.5 mm 1.050 r/min 55_ BTDC at 5.5 mm Full-transistor FE246BH (DENSO) No 75 X 95 cycles/min.8 mm 4.9 V SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS 3.88 X 7.1 X 14.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.

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– .

7 NOTE: After tightening to 15 Nm (1. tighten another 45_ X 50_ –11– .2 Remarks 4 0.0 6.5 mSkg).5 6.2 24 2.4 7 0.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 See NOTE 14 1.5 1.4 12 1.

First.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 0.5 5. then loosen the ring nut completely. tighten the ring nut to approximately 18 Nm (1. NOTE: 1.4 2.8 Remarks See NOTE. –12– .4 1.8 mSkg) with a torque wrench. Retighten the ring nut to specification.0 5.5 2. 2.9 4.

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– .

F Route the turn signal leads upper the headlight housing boss. C The speedometer lead with not be tighten.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. E Connect to the right front turn signal connectors. D Install the headlight relays onto the headlight housing bridge. B Route the meter assembly lead through the left side of the headlight housing. –20– .

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

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. 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.CABLE ROUTING Rollover valve (California only) Charcoal canister (California only) Rear brake switch lead Timing chain tensioner. H Insert the plastic clamp into the hole in the coolant reservoir’s tab. D Route the coolant reservoir breather hose over the timing chain tensioner. F Route the clutch cable between the radiator bracket and frame and in front of the thermostat assembly breather hose. G Route the clutch cable to the inside of the radiator inlet hose. 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). –22– .

clamp all of them at just behind of the air induction system protector and air induction system vacuum hose protector. –23– . coolant reservoir tank breather. B Through the air cleaner drain hose. air induction system hose and air induction system vacuum hose outside of the AC magneto lead. fuel tank over flow hose. fuel tank breather hose. moreover at under the three sides pipe.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. Then.

J Route the sidestand switch lead and oil level switch Route the seat lock cable over the wire harness. K Do not crush the water pump breather hose and Make sure the rear flasher light lead coupler and plastic clip. Fasten the wire harness with a plastic clamp. routing the hoses to the exterior of the under cowlH 50 mm ing. tail light lead coupler in the rubber cover. I Fasten the sidestand switch lead. 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– . plastic clip. lead to the inside of the drive sprocket 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.CABLE ROUTING C D E F SPEC To the connector cover.

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

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. E Fasten the EXUP cables and engine mount with a plastic locking tie. C Route the EXUP cables on the outside of the engine mount. –26– .CABLE ROUTING Speed sensor lead Charcoal canister (California only) EXUP cables EXUP A Route the EXUP cables behind the cross tube.

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– .

CABLE ROUTING A Make sure the headlight lead in the rubber cover. J Route the idle adjust cable upper the ground lead. D Route the thermo switch lead through the steel band on the radiator. SPEC G To the carburetor. speed sensor lead. K Fasten the fuel pump 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. Insert the plastic clamp into the hole on the frame. starter motor lead and EXUP cable with a plastic clamp. rear brake light lead. E Fasten the main harness and thermo switch lead with a plastic clamp. H Route the coolant reservoir tank breather hose upper the air vent surge tank. C Do not cross the throttle cables and right handlebar switch lead. F Route the ignition coil sub-wire harness under the throttle position sensor. –29– . fuel sender lead. neutral switch lead.

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

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

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

S Replace brake pads if necessary. S Clean. EB301000 PERIODIC MAINTENANCE AND LUBRICATION INTERVALS No. S Replace brake pads if necessary.000 km Every 10.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 valve clearance.000 km Every 20. S Check condition. S Adjust or replace cable. S S S S Check tread depth and for damage. S Check operation. these preventive maintenance procedures will ensure more reliable vehicle operation. S Adjust if necessary. S Adjust if necessary. S Correct if necessary. regap or replace if necessary.000 km After the first 1. S Lubricate with lithium soap base grease. S Lubricate with lithium soap base grease. S Replace if necessary. S Correct accordingly. Replace if necessary. No ITEM CHECKS AND MAINTENANCE JOBS S Check fuel hoses and vacuum hose for cracks or damage. S Check bearing play and Steering for roughness. Check air pressure. S Check balance. This information applies to vehicles already in service as well as to new vehicles that are being prepared for sale.000 km and after washing the motorcycle or riding in the rain 13 * Swingarm 14 Drive chain 15 * Steering bearings –33– . S Replace if necessary. S Correct accordingly.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 Check operation. S Replace if necessary. S Clean or replace if necessary. S Check swingarm pivoting point for play. S Check for cracks or damage. runout and for damage. S Correct accordingly. S Rebalance or replace if necessary. a longer service life and reduce the need for costly overhaul work. fluid level and vehicle for fluid leakage. S Check operation. S Replace if necessary. Correct if necessary. S Check condition. S Check chain slack. S Clean and lubricate. Every 40.000 km Every 1. All service technicians should be familiar with this entire chapter. Make sure that the rear wheel is properly aligned. If followed. Every 24. fluid level and vehicle for fluid leakage.

D The air filter needs more frequent service if you are riding in unusually wet or dusty areas. S Adjust headlight beam if necessary. S Replace the brake hoses every four years and if cracked or damaged. synchronization and starter operation.000 km Every 10. S Correct if necessary. S Check the screw clamp for looseness. S Every two years replace the internal components of the brake master cylinder and caliper.) S Replace.000 km or 20. NOTE: D The annual checks must be performed once a year unless a 10. S Adjust if necessary. S Correct if necessary. S Correct accordingly. S Check operation and shock absorber for oil leakage. if necessary. S Lubricate and repair if necessary. bolts and screws are properly tightened. –34– . S Check operation. S Check the air cut valve and reed valve for damage. S Check engine idling speed. S Correct if necessary. S Check operation. S Check oil level and vehicle for oil leakage. signals and switches 30 * * Since these items require special tools. S Check operation. S Lubricate if necessary.000 km maintenance was performed in the same year. No ITEM CHECKS AND MAINTENANCE JOBS S Make sure that all nuts. S Replace the entire air induction system if necessary. S Check operation and for oil leakage.000 km CHK ADJ Every 20. S Tighten if necessary. S Check operation. have a Yamaha dealer perform the service. D Hydraulic brake service S Regularly check and. After the first 1. data and technical skills. (Warm engine before draining. S Check coolant level and vehicle for coolant leakage. S Correct if necessary. S Correct accordingly. and change the brake fluid. S Tighten if necessary. S Change coolant. S Replace shock absorber assembly if necessary.PERIODIC MAINTENANCE AND LUBRICATION INTERVALS No. S Change. correct the brake fluid level. S Replace if necessary.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. 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.

reverse the removal procedure. 1 2 3 4 5 6 7 8 9 1 1 1 1 1 1 1 2 1 Front installation. Refer to “SEATS”. –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” and “FUEL TANK”. reverse the removal procedure.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– . For installation. Disconnect. 1 2 3 4 5 6 7 8 9 10 11 1 1 1 4 1 1 2 1 4 1/2 1 Loosen.

ENGINE CHK ADJ OVERHAULING THE ENGINE AIR INDUCTION SYSTEM 4 Nm (0. reverse the removal procedure.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. –37– . For installation.

5 mSkg) 40 Nm (4.4 mSkg) Order Job/Part Removing the engine Q’ty Remarks Remove the parts in the order listed. reverse the removal procedure.0 mSkg) 55 Nm (5.4 mSkg) 40 Nm (4.5 mSkg) 24 Nm (2. For installation. NOTE: Place a suitable stand under the frame and engine.ENGINE ENG ENGINE 24 Nm (2.4 mSkg) 55 Nm (5. 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. –38– .

Lubricate the rear mounting bolts 6 7 threads with lithium soap base grease.0 mSkg) Pinch bolts 10 11 24 Nm (2. and then tighten the self locking nut 9 . h.ENGINE EB400700 ENG INSTALLING THE ENGINE 1.0 mSkg) Left front mounting bolt 3 40 Nm (4. Install the spacer 1 to the frame. Tighten the self locking nut 8 . and washers 4 5 .5 mSkg) Right front mounting bolt 2 40 Nm (4. Temporally tighten the right front mounting bolt 2 . g. i. b. left front mounting bolt 3 . d. f. Tighten the pinch bolt 10 . Install the rear mounting bolts 6 7 and self locking nut 8 9 . c.4 mSkg) –39– . Tighten the pinch bolt 11 . e. Install: S engine assembly a. Tighten the left mounting bolt 3 . Tighten the right mouthing bolt 2 . Self locking nut 8 9 55 Nm (5.

1 2 3 1 1 2 For installation. Refer to “ENGINE”.CYLINDER HEAD EB402000 ENG CYLINDER HEAD 50 Nm (5. –40– .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. reverse the removal procedure. Refer to “CAMSHAFTS”.

Refer to “CYLINDER HEAD”. Refer to “GENERATOR”.0 mSkg) 10 Nm (1.CRANKCASE CRANKCASE ENG 10 Nm (1. Refer to “PICKUP COIL”. Refer to “CLUTCH”. 1 2 3 4 5 1 1 1 1 1 –41– . Refer to “OIL PAN AND OIL PUMP”. Refer to “ENGINE”.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.

–42– .0 mSkg) 10 Nm (1. reverse the removal procedure.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.CRANKCASE ENG 10 Nm (1.

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

25 65 mm bolt: 27 64 mm bolts: 16 . make sure that the transmission gears shift correctly when the shift drum assembly is turned by hand. Install: S crankcase bolts NOTE: S Lubricate the bolt threads with engine oil. S Tighten each bolt at 15 Nm in the tightening sequence cast on the crankcase. 25 X 28 12 Nm (1. 24 14 Nm (1. S Tighten bolts 11 to 28 as shown below. S Tighten bolts 1 to 10 45_ X 50_ more. 7.4 mSkg) Bolt 21 . 28 Bolt 1 X 10 15 Nm (1. 26 . 23 .5 mSkg) + 45_ X 50_ Bolt 11 X 15 . 19 . Install: S lower crankcase 1 (onto the upper crankcase 2 ) CAUTION: Before tightening the crankcase bolts. S Install a washer on bolts 1 X 10 .2 mSkg) Bolt 16 .4 mSkg) –44– . 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 . 22 24 Nm (2. 24 60 mm bolt: 23 55 mm bolts: 11 X 15 50 mm bolt: 18 45 mm bolts: 20 . 17 X 20 . S Loosen each bolt one time and tighten 15 Nm in the same sequence.CRANKCASE ENG 6.

0 mSkg) 9 Nm (0.9 mSkg) 23 Nm (2.5 Nm (0. Refer to “ENGINE” in chapter 4. 1 2 3 4 Coolant reservoir breather hose Coolant reservoir hose Coolant reservoir Thermo unit coupler 1 1 1 1 Disconnect. Refer to “COWLINGS” in chapter 3. Drain.0 mSkg) 20 Nm (2. Refer to “CHANGING THE COOLANT” in chapter 3. –45– .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.3 mSkg) 4. Refer to “AIR FILTER CASE AND IGNITION COIL PLATE” in chapter 3.RADIATOR EB500000 COOL COOLING SYSTEM RADIATOR 10 Nm (1. Refer to “SEATS” and “FUEL TANK” in chapter 3.

Remarks Disconnect. Disconnect.RADIATOR COOL 10 Nm (1.9 mSkg) 23 Nm (2.0 mSkg) 9 Nm (0. –46– .3 mSkg) 4. For installation. reverse the removal procedure.5 Nm (0.45 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.0 mSkg) 20 Nm (2.

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

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– .

Check: S air cutoff valve Cracks/damage ! Replace. Cracks/damage ! Replace.4 mm 1 Surface plate 4.AIR INDUCTION SYSTEM EAS00510 CARB CHECKING THE AIR INDUCTION SYSTEM 1. 3. Check: S hoses Loose connection ! Connect properly. S pipes Cracks/damage ! Replace. Measure: S fibre reed bending limit a Out of specification ! Replace the reed valve. 2. Fibre reed bending limit 0. –49– . Check: S fibre reed 1 S fibre reed stopper S reed valve seat S Cracks/damage ! Replace.

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.0 mSkg) 18 Nm (1. reverse the removal procedure. Refer to “INSTALLING THE FRONT WHEEL”. –50– . For installation.8 mSkg) Order Job/Part Removing the front wheel and brake discs Q’ty Remarks Remove the parts in the order listed.6 mSkg) 72 Nm (7.2 mSkg) 40 Nm (4.FRONT WHEEL AND BRAKE DISCS EB700002 CHAS CHASSIS FRONT WHEEL AND BRAKE DISCS 6 Nm (0. NOTE: Place the motorcycle on a suitable stand so that the front wheel is elevated.

3 mSkg) NOTE: When front wheel is installed to front fork. Lubricate: S wheel axle S oil seal lips Recommended lubricant Lithium soap base grease 2.FRONT WHEEL AND BRAKE DISCS EB700725 CHAS INSTALLING THE FRONT WHEEL 1. –51– . push down hard on the handlebars several times and check if the front fork rebounds smoothly.2 mSkg) 23 Nm (2. make sure that wheel axle 1 top end side and front fork end side are align a together. CAUTION: Before tightening the wheel axle nut. 4. Then. Install: S brake discs 1 18 Nm (1. 3.0 mSkg) WARNING Make sure that the brake hose is routed properly. Install: S brake calipers 40 Nm (4.8 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. tighten wheel axle pinch bolt 2 . S Tighten the brake disc bolts in stages and in a crisscross pattern.

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.5 mSkg) 30 Nm (3. –52– . reverse the removal procedure. Drain.FRONT AND REAR BRAKES EB702202 CHAS FRONT AND REAR BRAKES REAR BRAKE MASTER CYLINDER AND BRAKE FLUID RESERVOIR 5 Nm (0.0 mSkg) 23 Nm (2. 1 2 3 4 5 6 7 8 9 10 1 1 1 1 1 1 1 2 1 1 For installation.

Shift the transmission into the neutral position or pull the clutch lever. 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. ” High beam indicator light “ This indicator comes on when the headlight high beam is used. When this occurs. 3.INSTRUMENT FUNCTIONS ELEC ELECTRICAL INSTRUMENT FUNCTIONS INDICATOR LIGHTS Neutral indicator light “ ” This indicator light comes on when the transmission is in the neutral position. –53– . Refer to “SELF-DIAGNOSIS”. but this is not a malfunction. 3. Turn signal indicator light “ ” This indicator light flashes when the turn signal switch is pushed to the left or right. 2. Oil level warning light “ ” This warning light comes on when the engine oil level is low.8 L. If the warning light does not come on while pushing the start switch. If the warning light does not come on while pushing the start switch. The electrical circuit of the warning light can be checked according to the following procedure. Shift the transmission into the neutral position or pull the clutch lever. refuel as soon as possible. NOTE: Even if the oil level is sufficient. NOTE: This model is equipped with a selfdiagnosis device for the fuel level warning light circuit. 1. Set the engine stop switch to “ ” and turn the key to “ON”. The electrical circuit of the warning light can be checked according to the following procedure. have a Yamaha dealer check the electrical circuit. have a Yamaha dealer check the electrical circuit. 1. Push the start switch. Push the start switch. the warning light may flicker when riding on a slope or during sudden acceleration or deceleration. 2. Set the engine stop switch to “ ” and turn the key to “ON”.

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

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). –55– . NOTE: After resetting the fuel reserve tripmeter. it will reset itself automatically and the display will return to “TRIP 1” after refueling and traveling 5 km. the display will return to “TRIP 1”. In that case. the odometer display will automatically change to the fuel reserve tripmeter mode “TRIP F” and start counting the distance traveled from that point. select it by pushing the “SELECT” button. the display automatically returns to the prior mode. If you do not reset the fuel reserve tripmeter manually. and then push the “RESET” button. in that case. unless a different mode had been previously selected. 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.

) Current engine speed for 3 seconds –56– . Push the “SELECT” button and “RESET” button together for at least two seconds. and the minute digits will start flashing. 5. When the hour digits start flashing. Push the “SELECT” button. 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 “SELECT” button. 2. Push the “SELECT” button and then release it to start the clock. push the “SELECT” button for at least one second. 3. CAUTION: Do not operate the engine in the tachometer red zone. Push the “RESET” button to set the minutes. push the “RESET” button to set the hours.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. To set the clock: 1.INSTRUMENT FUNCTIONS ELEC Clock mode To change the display to the clock mode. Red zone: 11. 4.5 seconds (See the table below. Tachometer The electric tachometer allows the rider to monitor the engine speed and keep it within the ideal power range. To change the display back to the odometer modes.

Refer to “SEATS” in chapter 3. Refer to “COWLINGS” in chapter 3. Refer to “FUEL TANK” in chapter 3. 1 2 3 4 1 1 1 1 For installation.ELECTRIC STARTING SYSTEM ELECTRIC STARTING SYSTEM STARTER MOTOR 5 Nm (0. –57– .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.5 mSkg) 7 Nm (0. reverse the removal procedure.

ELECTRIC STARTING SYSTEM EB803501 ELEC 5 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. For assembly. reverse the disassembly procedure –58– .

5 mm NOTE: The mica must be undercut to ensure proper operation of the commutator. Min. Measure the armature assembly resistances with the pocket tester. Measure: S commutator diameter a Out of specification ! Replace the starter motor.5 mm 3. commutator diameter 23. Check: S commutator Dirt ! Clean with 600 grit sandpaper. replace the starter motor. –59– . 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. Measure: S armature assembly resistances (commutator and insulation) Out of specification ! Replace the starter motor. 4.ELECTRIC STARTING SYSTEM EB803511 ELEC Checking The Starter Motor 1. a. If any resistance is out of specification. Mica undercut 1. 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.

28 X 7. Install: S armature 1 –60– . Min. 8.ELECTRIC STARTING SYSTEM ELEC 5. Measure: S brush length a Out of specification ! Replace the brushes as a set. Check: S gear teeth Damage/wear ! Replace the gear. 2. Check: S bearing S oil seal Damage/wear ! Replace the defective part(-s). Brush spring force 5. 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. Measure: S brush spring force Out of specification ! Replace the brush springs as a set. brush length 3.92 N 7. EB803701 Assembling The Starter Motor 1.

Install: S starter motor yoke 2 S O-rings 1 New S starter motor rear cover 3 S bolts 5 Nm (0.5 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. –61– .

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– .

however. Main. 2. radiator fan motor 5. main switch 4. main. Speedometer 7. remove the following part(-s). and radiator fan motor fuses for continuity. Fan motor relay 6. signal system. Wiring (the entire cooling system) NOTE: S Before troubleshooting. EB802411 CAUTION: S If the engine is kept running at over 1. battery 3. S Recharge or replace the battery. signal system. and radiator fan motor fuses 2. is not trouble. Refer to “CHECKING AND CHARGING THE BATTERY” in chapter 3. This. even when the coolant temperature is low enough. Main switch S Check the main switch for continuity. 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). S Does the radiator fan motor turn? YES NO –63– . S Keep hands and other body regions away to avoid injury. Refer to “CHECKING THE FUSES” in chapter 3. Check: 1. EB807400 NO the main 4. S Are the main.COOLING SYSTEM EB807010 EB802401 ELEC TROUBLESHOOTING S The radiator fan motor fails to turn. signal system. S Connect the battery (12 V) as shown. Pocket tester 90890-03112 EB802400 3. The radiator fan motor is faulty and must be replaced. and radiator fan motor fuses OK? YES NO Replace the fuse(-s). S The coolant temperature meter needle fails to move when the engine is warm. Refer to “CHECKING THE SWITCHES”.500 rpm for at least one minute with the switch remaining placed in neutral position and the throttle valve fully open. Battery positive lead ! blue 1 Battery negative lead ! black 2 1. Open-circuit voltage 12.8 V or more at 20_C S Is the battery OK? YES NO S Clean the battery terminals. the radiator fan motor will start rotating. Thermo unit 8. signal system and radiator fan motor fuses S Check the main. Radiator fan motor S Disconnect the radiator fan motor coupler from the wire harness. Battery S Check the condition of the battery. S Is the main switch OK? YES Replace switch.

Battery positive lead ! brown 1 Battery negative lead ! green/black 2 Tester positive prove ! brown 3 Tester negative prove ! blue 4 7.COOLING SYSTEM EB807400 EB807402 ELEC 5. NOTE: Make sure that the thermo unit terminals do not get wet. S Never subject the thermo unit to strong shocks. EB807400 6.4 kΩ at 50_C 3.9 kΩ at 105_C 1. S Connect the pocket tester (Ω 1) to the thermo unit 1 as shown.1 X 1. If the thermo unit is dropped.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. Thermo unit 23 Nm (2. replace it. S Place a thermometer 3 in the coolant. then let it cool to the specified temperature as indicated in the table. WARNING S Does the coolant temperature display “HI” and warning light comes on? YES NO The speedometer is faulty and must be repaired.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. Thermo unit 9. S Connect the green/red 1 and black/blue 2 terminals with a jumper lead 3 as shown. Thermo unit S Remove the thermo unit from the radiator. S Handle the thermo unit with special care.4 X 4. S Immerse the thermo unit in a container filled with coolant 2 . Speedometer S Disconnect the thermo unit coupler.6 X 1. S Set the main switch to “ON”. Fan motor relay S Disconnect the fan motor relay coupler.3 mSkg) Three bond sealock® 10 –64– .7 X 11. S Check the thermo unit for continuity at the temperatures indicated in the table.

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/ B .. Dg . .. Br/ W . L . O/R .. . 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 .. G . .. .. Br/ R .. . . .. . .. . R. R/ G . . R/ Y .. . . G/W . Br/ L . Gy . Br . W/ B .. . B/ R . R/ W . . . . . . . B/ Y . .. O . W/ Y . . . . . . . .. Ch .. .. W/ G . . G/Y .. .. . Y/ L . L/Y .. . black brown chocolate dark green green gray blue orange pink red Sb . . green / red green / white green / yellow blue/ black blue/ red blue/ white blue/ yellow orange / red red / black red / green R/ L .YZF-R1 WIRING DIAGRAM (For EUR) COLOR CODE B . L/B . P . Y .. L/W .. . ... . sky blue white yellow black/ blue black/ red black/ white black/ yellow brown/ blue brown/ red brown/ white G/R . .. L/R . . .. B/ W . . B/ L .. . ... W . Y/ B . . . . ..

. . L/R ... R. . 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 . . . Ch . L . .. Dg . ... green / red green / white green / yellow blue/ black blue/ red blue/ white blue/ yellow orange / red red / black red / green R/ L . Y/ B .. . Br .... W .. . .. sky blue white yellow black/ blue black/ red black/ white black/ yellow brown/ blue brown/ red brown/ white G/R . .. O .. . .. . W/ B .. Br/ W .. .. B/ Y . . . . . ... . . . Br/ L .. R/ G . . B/ W . B/ R .. . O/R . L/W . . . . R/ 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 . Y/ L . . Gy . .. G/Y . P . . . . Y . G/W . W/ Y . . R/ W . .. G . . W/ G . . . . . . . ... L/B . black brown chocolate dark green green gray blue orange pink red Sb . Br/ R . . . B/ L ... L/Y . . R/ B .

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