yamaha yzfr1 00 service manual

FOREWORDThis Supplementary Service Manual has been prepared to introduce new service and data for theYZF-R1 2000. For complete service information procedures it is necessary to use this SupplementaryService Manual together with the following manual.

YZF-R1 SERVICE MANUAL: 4XV1-AE1

YZF-R1 2000SUPPLEMENTARYSERVICE MANUAL

1999 by Yamaha Motor Co., Ltd.First Edition, December 1999

Any reproduction or unauthorized usewithout the written permission of

Yamaha Motor Co., Ltd. is expresslyprohibited.

NOTE:

WARNING

CAUTION:

EB001000

NOTICEThis manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha dealersand their qualified mechanics. it is not possible to include all the knowledge of a mechanic in one manu-al. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehiclesshould have a basic understanding of mechanics and the techniques to repair these types of vehicles.Repair and maintenance work attempted by anyone without this knowledge is likely to render the ve-hicle unsafe and unfit for use.

Yamaha Motor Company, Ltd. is continually striving to improve all of its models. Modifications and sig-nificant changes in specifications or procedures will be forwarded to all authorized Yamaha dealersand will appear in future editions of this manual where applicable.

Designs and specifications are subject to change without notice.

EB002000

IMPORTANT MANUAL INFORMATIONParticularly important information is distinguished in this manual by the following.

The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOURSAFETY IS INVOLVED!

Failure to follow WARNING instructions could result in severe injury or death tothe motorcycle operator, a bystander or a person checking or repairing the mo-torcycle.

A CAUTION indicates special precautions that must be taken to avoid damageto the motorcycle.

NOTE: A NOTE provides key information to make procedures easier or clearer.

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EB003000

HOW TO USE THIS MANUALThis manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensiveexplanations of all installation, removal, disassembly, assembly, repair and check procedures are laidout with the individual steps in sequential order.1

The manual is divided into chapters. An abbreviation and symbol in the upper right corner of eachpage indicate the current chapter.Refer to SYMBOLS.2

Each chapter is divided into sections. The current section title is shown at the top of each page,except in Chapter 3 (PERIODIC CHECKS AND ADJUSTMENTS), where the sub-section title(-s) ap-pears.3

Sub-section titles appear in smaller print than the section title.4

To help identify parts and clarify procedure steps, there are exploded diagrams at the start of eachremoval and disassembly section.5

Numbers are given in the order of the jobs in the exploded diagram. A circled number indicates adisassembly step.6

Symbols indicate parts to be lubricated or replaced.Refer to SYMBOLS.7

A job instruction chart accompanies the exploded diagram, providing the order of jobs, names ofparts, notes in jobs, etc.8

Jobs requiring more information (such as special tools and technical data) are described sequen-tially.

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1

3

5

7

9

2

4

8

6

24 25

2321

19 2018

16 1715

1413

11 12

10

GENINFO SPEC

ENG

CARB

ELECCHAS

COOL

CHKADJ

TRBLSHTG

EB004000

SYMBOLSThe following symbols are not relevant to everyvehicle.Symbols 1 to 9 indicate the subject of eachchapter.1 General information2 Specifications3 Periodic checks and adjustments4 Engine5 Cooling system6 Carburetor(-s)7 Chassis8 Electrical system9 Troubleshooting

Symbols 10 to 17 indicate the following.10 Serviceable with engine mounted11 Filling fluid12 Lubricant13 Special tool14 Tightening torque15 Wear limit, clearance16 Engine speed17 Electrical data

Symbols 18 to 23 in the exploded diagrams indi-cate the types of lubricants and lubricationpoints.18 Engine oil19 Gear oil20 Molybdenum disulfide oil21 Wheel bearing grease22 Lithium soap base grease23 Molybdenum disulfide greaseSymbols 24 to 25 in the exploded diagrams indi-cate the following.24 Apply locking agent (LOCTITE)25 Replace the part

CONTENTSSPECIFICATIONS

GENERAL SPECIFICATIONS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE SPECIFICATIONS 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHASSIS SPECIFICATIONS 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ELECTRICAL SPECIFICATIONS 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . TIGHTENING TORQUES 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ENGINE TIGHTENING TORQUES 11. . . . . . . . . . . . . . . . . . . . . . . . . CHASSIS TIGHTENING TORQUES 12. . . . . . . . . . . . . . . . . . . . . . .

LUBRICATION POINTS AND LUBRICANT TYPES 13. . . . . . . . . . . . . ENGINE LUBRICATION POINTS AND LUBRICANT TYPES 13. .

OIL FLOW DIAGRAMS 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . COOLANT FLOW DIAGRAMS 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CABLE ROUTING 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PERIODIC CHECKS AND ADJUSTMENTSINTRODUCTION 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PERIODIC MAINTENANCE AND LUBRICATION INTERVALS 33. . . COWLINGS 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AIR FILTER CASE AND IGNITION COIL PLATE 36. . . . . . . . . . . . . . .

OVERHAULING THE ENGINEAIR INDUCTION SYSTEM 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

INSTALLING THE ENGINE 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CYLINDER HEAD 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CRANKCASE 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ASSEMBLING THE CRANKCASE 43. . . . . . . . . . . . . . . . . . . . . . . . .

COOLING SYSTEMRADIATOR 45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CARBURETORSAIR INDUCTION SYSTEM 47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AIR INJECTION 47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AIR CUTOFF VALVE 47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AIR INDUCTION SYSTEM DIAGRAMS 48. . . . . . . . . . . . . . . . . . . . . CHECKING THE AIR INDUCTION SYSTEM 49. . . . . . . . . . . . . . . .

CHASSISFRONT WHEEL AND BRAKE DISCS 50. . . . . . . . . . . . . . . . . . . . . . . . .

INSTALLING THE FRONT WHEEL 51. . . . . . . . . . . . . . . . . . . . . . . . FRONT AND REAR BRAKES 52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

REAR BRAKE MASTER CYLINDER AND BRAKE FLUID RESERVOIR 52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ELECTRICALINSTRUMENT FUNCTIONS 53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

INDICATOR LIGHTS 53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . COOLANT TEMPERATURE WARNING LIGHT 54. . . . . . . . . . . . . . SPEEDOMETER UNIT 55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ELECTRIC STARTING SYSTEM 57. . . . . . . . . . . . . . . . . . . . . . . . . . . . . STARTER MOTOR 57. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

COOLING SYSTEM 62. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CIRCUIT DIAGRAM 62. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING 63. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SELF-DIAGNOSIS 66. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING 67. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

YZF-R1 WIRING DIAGRAM (For EUR)

YZF-R1 WIRING DIAGRAM (For OCE)

1

GENERAL SPECIFICATIONS SPEC

SPECIFICATIONSGENERAL SPECIFICATIONS

Item Standard LimitDimensionsOverall length

Overall widthOverall heightSeat heightWheelbaseMinimum ground clearanceMinimum turning radius

2,035 mm2,095 mm (for AUS)695 mm1,105 mm815 mm1,395 mm140 mm3,400 mm

WeightWet (with oil and a full fuel tank)Dry (without oil and fuel)Maximum load (total of cargo, rider,passenger, and accessories)

194 kg175 kg201 kg

2

ENGINE SPECIFICATIONS SPEC

Temp.

ENGINE SPECIFICATIONSItem Standard Limit

EngineEngine typeDisplacementCylinder arrangementBore strokeCompression ratioEngine idling speedVacuum pressure at engine idlingspeedStandard compression pressure(at sea level)

Liquid-cooled, 4-stroke, DOHC998 cm3Forward-inclined parallel 4-cylinder74 58 mm11.8 : 11,000 1,100 r/min29.3 kPa (220 mm Hg)

1,450 kPa (14.5 kgf/cm2) at 400 r/min

FuelRecommended fuel

Fuel tank capacityTotal (including reserve)Reserve only

Regular unleaded gasolineUnleaded fuel (for AUS)

18 L3.8 L

Engine oilLubrication systemRecommended oil

QuantityTotal amountWithout oil filter cartridgereplacementWith oil filter cartridge replacement

Oil pressure (hot)

Relief valve opening pressure

Wet sump

SAE20W40SE or SAE10W30SE

3.6 L2.7 L

2.9 L45 kPa at 1,100 r/min(0.45 kgf/cm2 at 1,100 r/min)490 570 kPa (4.9 5.7 kgf/cm2)

3


Item Standard LimitCamshaftsDrive systemCamshaft cap inside diameterCamshaft journal diameterCamshaft-journal-to-camshaft-cap clearanceIntake camshaft lobe dimensions

Measurement AMeasurement BMeasurement C

Exhaust camshaft lobe dimensions

Measurement AMeasurement BMeasurement C

Max. camshaft runout

Chain drive (right)24.500 24.521 mm24.459 24.472 mm0.028 0.062 mm

32.5 32.6 mm24.95 25.05 mm7.45 7.65 mm

32.95 33.05 mm24.95 25.05 mm7.75 7.95 mm

32.4 mm24.85 mm

32.85 mm24.85 mm

0.03 mm

4


Head Diameter Face Width Seat Width Margin Thickness

Item Standard LimitValves, valve seats, valve guidesValve clearance (cold)IntakeExhaust

Valve dimensions

0.11 0.20 mm0.21 0.25 mm

Valve head diameter AIntakeExhaust

Valve face width BIntakeExhaust

Valve seat width CIntakeExhaust

Valve margin thickness DIntakeExhaust

Valve stem diameterIntakeExhaust

Valve guide inside diameterIntakeExhaust

Valve-stem-to-valve-guide clearanceIntakeExhaust

Valve stem runout

Valve seat widthIntakeExhaust

22.9 23.1 mm24.4 24.6 mm

1.76 2.90 mm1.76 2.90 mm

0.9 1.1 mm0.9 1.1 mm

0.5 0.9 mm0.5 0.9 mm

3.975 3.990 mm4.465 4.480 mm

4.000 4.012 mm4.500 4.512 mm

0.010 0.037 mm0.020 0.047 mm

0.9 1.1 mm0.9 1.1 mm

3.945 mm4.43 mm

4.05 mm4.55 mm

0.08 mm0.1 mm0.01 mm

Connecting rodsCrankshaft-pin-to-big-end-bearingclearanceBearing color code

0.031 0.055 mm

1 = Violet 0 = White 1 = Blue 2 = Black

5


Item Standard LimitTransmissionTransmission typePrimary reduction systemPrimary reduction ratioSecondary reduction systemSecondary reduction ratioOperationGear ratios1st gear2nd gear3rd gear4nd gear5th gear6th gear

Max. main axle runoutMax. drive axle runout

Constant mesh, 6-speedSpur gear68/43 (1.581)Chain drive43/16 (2.688)Left-foot operation

35/14 (2.500)35/19 (1.842)30/20 (1.500)28/21 (1.333)30/25 (1.200)29/26 (1.115)

0.08 mm0.08 mm

CarburetorsModel (manufacturer) quantityThrottle cable free play (at theflange of the throttle grip)ID markMain jetMain air jet

Jet needleNeedle jetPilot air jetPilot outletPilot jetBypass 1Bypass 2Bypass 3Pilot screw turns outValve seat size

BDSR40 (MIKUNI) 43 5 mm

5JJ1 00#130Carburetors 1 and 4: #60Carburetors 2 and 3: #656DEY5-53-3P-OM#1201.0#150.80.90.83.1251.5

6

CHASSIS SPECIFICATIONS SPEC

CHASSIS SPECIFICATIONSItem Standard Limit

Front tireTire typeSizeModel (manufacturer)

Tire pressure (cold)0 90 kg90 197 kgHigh-speed riding

Min. tire tread depth

Tubeless120/70 ZR17 (58W)MEZ3Y FRONT (METZELER)D207FQ (DUNLOP)

250 kPa (2.5 kg/cm2, 2.5 bar)250 kPa (2.5 kg/cm2, 2.5 bar)250 kPa (2.5 kg/cm2, 2.5 bar)

1.6 mmRear tireTire typeSizeModel (manufacturer)Tire pressure (cold)0 90 kg90 197 kgHigh-speed riding

Min. tire tread depth

Tubeless190/50 ZR17 (73W)MEZ3Y (METZELER)/D207N (DUNLOP)

250 kPa (2.5 kg/cm2, 2.5 bar)290 kPa (2.9 kg/cm2, 2.9 bar)250 kPa (2.5 kg/cm2, 2.5 bar)

1.6 mmRear brakeBrake typeOperationBrake pedal position (from the topof the brake pedal to the bottom ofthe rider footrest bracket)Recommended fluidBrake discsDiameter thicknessMin. thicknessMax. deflectionBrake pad lining thickness

Master cylinder inside diameterCaliper cylinder inside diameter

Single-disc brakeRight-foot operation35 40 mm

DOT 4

245 5 mm

5.5 mm

12.7 mm38.2 mm

4.5 mm0.1 mm0.5 mm

7


Item Standard LimitFront suspensionSuspension typeFront fork typeFront fork travelSpringFree lengthSpacer lengthInstalled lengthSpring rate (K1)Spring stroke (K1)

Optional spring availableFork oilRecommended oilQuantity (each front fork leg)Level (from the top of the innertube, with the inner tube fullycompressed, and without thefork spring)

Damper adjusting rod locknutdistanceSpring preload adjusting positionsMinimumStandardMaximum

Rebound damping adjustingpositionsMinimum*Standard*Maximum*

Compression damping adjustingpositionsMinimum*Standard*Maximum*

*with the adjusting screw fully turnedin position

Telescopic forkCoil spring/oil damper135 mm

255 mm85 mm242.4 mm7.35 N/mm (0.75 kgf/mm)0 135 mmNo

Suspension oil 01 or equivalent482 cm374 mm

11 mm

861

1151

951

8


Item Standard LimitRear suspensionSuspension typeRear shock absorber assemblytypeRear shock absorber assemblytravelSpringFree lengthInstalled lengthSpring rate (K1)Spring stroke (K1)

Optional spring availableStandard spring preload gas/airpressureSpring preload adjusting positionsMinimumStandardMaximum

Rebound damping adjustingpositionsMinimum*Standard*Maximum*

Compression damping adjustingpositionsMinimum*Standard*Maximum*

*with the adjusting screw fully turnedin position

Swingarm (link suspension)Coil spring/gas-oil damper

65 mm

176 mm162.5 mm78.4 N/mm (7.84 kgf/mm)0 65 mmNo1,200 kPa (12 kgf/cm2)

149

1171

1191

9

ELECTRICAL SPECIFICATIONS SPEC

ELECTRICAL SPECIFICATIONSItem Standard Limit

System voltage 12 V Ignition systemIgnition system typeIgnition timingAdvanced timingAdvancer typePickup coil resistance/colorTransistorized coil ignition unitmodel (manufacturer)

Transistorized coil ignition5 BTDC at 1,050 r/min55 BTDC at 5,000 r/minThrottle position sensor and electrical248 372 W/Gy-BTNDF54 (DENSO)

Voltage regulatorRegulator typeModelNo-load regulated voltage

Semiconductor short circuitSH650A-1214.1 14.9 V

Bulbs (voltage/wattage quantity)HeadlightAuxiliary lightTail /brake lightTurn signal lightMeter light

12 V 60 W/55 W 212 V 5 W 212 V 5 W/21 W 212 V 21 W 4LED

Electric starting systemSystem typeStarter motorModel (manufacturer)Power outputBrushesOverall lengthSpring force

Commutator resistanceCommutator diameterMica undercut

Constant mesh

5JJ (YAMAHA)0.75 kW

9.8 mm4.88 7.32 N (488 732 gf)0.009 0.011 24.5 mm1.5 mm

3.65 mm

23.5 mm

Turn signal relayRelay typeModel (manufacturer)Self-cancelling device built-inTurn signal blinking frequencyWattage

Full-transistorFE246BH (DENSO)No75 95 cycles/min.21 W 2

Oil level switch model(manufacturer)

4XV (DENSO)

Fuel pump relay model(manufacturer)

G8R-30Y-M (OMRON)

10

ELECTRICAL SPECIFICATIONS SPEC

Item Standard LimitThermo unitModel (manufacturer) 5JJ (NIPPON THERMOSTAT)

Fuses (amperage quantity)Main fuseHeadlight fuseSignaling system fuseIgnition fuseRadiator fan fuseBackup fuse (odometer)Reserve fuse

30 A 120 A 120 A 115 A 110 A 110 A 130 A 120 A 115 A 110 A 1

11

TIGHTENING TORQUES SPEC

NOTE:

TIGHTENING TORQUESENGINE TIGHTENING TORQUES

Item Fastener Threadsize Qty

Tighteningtorque Remarks

size yNm mkgf

Cylinder headCylinder headGenerator rotorOil /water pump assembly drivensprocket coverAir induction system hoseCrankcaseCrankcaseCrankcaseCrankcaseIgnitor unit

NutCap nut

BoltBolt

ClampBoltBoltBoltBolt

Screw

M10M10M10M6

M7M9M6M6M8M5

8211

4102

1422

50656512

4

1412247

5.06.56.51.2

0.4

1.41.22.40.7

After tightening to 15 Nm (1.5 mkg), tighten another 45 50

See NOTE

12

TIGHTENING TORQUES SPEC

NOTE:

CHASSIS TIGHTENING TORQUES

Item Thread sizeTightening

RemarksItem Thread sizeNm mkgf

Remarks

Lower ring nutEngine mountingFront mounting boltsRear upper mounting boltRear under mounting boltsPinch boltsExhaust pipe bracket

Rear master cylinder

M30

M10M10M10M8M8M8

9

405555242418

0.9

4.05.55.52.42.41.8

See NOTE.

1. First, tighten the ring nut to approximately 18 Nm (1.8 mkg) with a torque wrench, then loosen thering nut completely.

2. Retighten the ring nut to specification.

13

LUBRICATION POINTS AND LUBRICANT TYPES SPECE202000

LUBRICATION POINTS AND LUBRICANT TYPESENGINE LUBRICATION POINTS AND LUBRICANT TYPES

Lubrication point LubricantConnecting rod bolts and nuts

14

OIL FLOW DIAGRAMS SPEC

1 Intake camshaft2 Exhaust camshaft3 Crankshaft4 Oil cooler5 Oil pipe6 Oil strainer7 Oil pump

EB203000

OIL FLOW DIAGRAMS

15

1 Exhaust camshaft2 Intake camshaft3 Oil filter


16

1 Cylinder head2 Crankshaft


17

COOLANT FLOW DIAGRAMS SPEC

1 Thermostat2 Radiator cap3 Coolant reservoir4 Radiator5 Oil cooler6 Water jacket joint

EB203000

COOLANT FLOW DIAGRAMS

18

1 Thermostat housing2 Water pump3 Radiator4 Radiator fan


19

1 Radiator2 Thermo unit


20

CABLE ROUTING SPEC

A Properly insert the meter assembly coupler and rubber boot into themeter assembly.

B Route the meter assembly lead through the left side of the headlighthousing.

C The speedometer lead with not be tighten.D Install the headlight relays onto the headlight housing bridge.E Connect to the right front turn signal connectors.F Route the turn signal leads upper the headlight housing boss.

1 Clutch cable2 Left handlebar switch lead3 Starter cable4 Main switch lead5 Steering cover

EB206000

CABLE ROUTING

21

N Route the thermo switch/ temperature sender sub-wire harness to the outside of the radiator cap.

O Route the right handlebar switch lead behind thethrottle cables. Do not cross the throttle cables andthe right handlebar switch lead.

P Route the right handlebar switch lead in front of thethrottle cables.

G Fasten the headlight lead with a plastic clamp atwhite tape mark.

H Fasten the wire harness to the headlight housingboss with a plastic locking tie.

I Route the headlight lead through the plastic guide.J Route the throttle cable to the front side of the brake

hose.K Route the clutch cable behind the front fork leg.L Make sure that the horn leads face out.M Route the throttle cables and right handlebar

switch lead between the lower bracket and steeringcover.

CABLE ROUTING SPEC

22

C Route the rollover-valve-to-fuel-tank hose to the in-side of the fuel hose (California only).

D Route the coolant reservoir breather hose over thetiming chain tensioner.

E Insert the plastic clip through the hole in the plasticframe panel and then fasten the wire harness andcoolant reservoir breather hose with it.

F Route the clutch cable between the radiator brack-et and frame and in front of the thermostat assem-bly breather hose.

G Route the clutch cable to the inside of the radiatorinlet hose.

H Insert the plastic clamp into the hole in the coolantreservoirs tab.

1 Rollover valve (California only)2 Charcoal canister (California only)3 Rear brake switch lead4 Timing chain tensioner.5 Thermostat assembly breather hose6 Radiator inlet hose7 Coolant reservoir breather hose8 Clutch cable9 Pickup coil leadA Fasten the starter motor lead to the flame which is

just before the side cover stay (0 5 mm) with aplastic clamp.

B 0 5 mm

CABLE ROUTING SPEC

23

12 Fuel tank overflow hose and fuel tank breather hose13 Drive chain sprocket cover14 Coolant hose15 EXUP servomotorA Route the air filter case breather hose and air induction system hose

to the inside of the wire harness.B Through the air cleaner drain hose, coolant reservoir tank breather,

fuel tank breather hose, fuel tank over flow hose, air induction systemhose and air induction system vacuum hose outside of the AC mag-neto lead. Then, clamp all of them at just behind of the air inductionsystem protector and air induction system vacuum hose protector,moreover at under the three sides pipe.

1 Starter cable2 Air induction system vacuum

hose3 Air induction system hose4 Sidestand switch lead5 Oil level switch lead6 Clamp7 Right handlebar switch lead8 Throttle cables9 Air guide10 Air filter case breather hose11 Coolant reservoir breather hose

CABLE ROUTING SPEC

24

CABLE ROUTING SPECJ Route the sidestand switch lead and oil level switch

lead to the inside of the drive sprocket cover.K Do not crush the water pump breather hose and

plastic clip.L Pass the fuel tank breather hose and the air filter

drain hose through the steel clamps and then afterrouting the hoses to the exterior of the under cowl-ing, align the leading ends of the hoses.

M Route the engine oil level switch lead and side-stand switch lead inside the coolant hose.

C To the connector cover.D Route the seat lock cable over the wire harness.E Fasten the wire harness with a plastic clamp.F Make sure the rear flasher light lead coupler and

tail light lead coupler in the rubber cover.G Route the rear turn signal lead through the hole in the

upper rear fender.H 50 mmI Fasten the sidestand switch lead, engine oil level

switch lead, and water pump breather hose with aplastic clip.

25

Q To the air filter.R To the fuel tank.S Insert the fuel tank breather hose into a back side

nipple of fuel tank. The fuel tank nipple and the fueltank breather hose have each white mark.

T Insert the fuel tank over flow hose into a front sidenipple of fuel tank.

U To the air vent surge tank.V Adjust the all clips direction to back side of the

body.W Clamp under a three sides pipe.

N Pass the fuel tank breather hose and the air filterdrain hose through the inside of the coolant hose.No hose must be inserted into the under cowling.

O Pass the air filter drain hose and the coolant reser-voir hose through the inside of the coolant hoseand route the leading ends to the bottom of thecoolant hose. The leading ends must not protrudefrom the under cowling.

P Fasten the air filter drain hose, coolant hose, cool-ant reservoir tank breather hose, fuel tank breatherhose, fuel tank drain hose and air induction systemhose at the steel clamp.

CABLE ROUTING SPEC

26

D Route the EXUP cables behind the swing arm headpipe.

E Fasten the EXUP cables and engine mount with aplastic locking tie.

1 Speed sensor lead2 Charcoal canister (California only)3 EXUP cables4 EXUPA Route the EXUP cables behind the cross tube.B Route the neutral switch lead direct to upper right

side.C Route the EXUP cables on the outside of the en-

gine mount.

CABLE ROUTING SPEC

27

13 Neutral switch connector14 Battery negative lead15 Rear brake switch coupler16 Speed sensor coupler17 EXUP cable18 Fuel tank overflow hose19 Fuel tank breather hose (except for California)20 Tail light lead21 Rear flasher light lead22 Crankcase breather hose23 Generator coupler24 Sidestand switch coupler

CABLE ROUTING SPEC1 Headlight sub-wire harness2 Left handlebar switch lead3 Main switch lead4 Starter cable5 Right handlebar switch coupler6 Throttle cables7 Engine air vent hose8 EXUP servomotor coupler9 Air vent surge tank10 Starter motor lead11 Pickup coil coupler12 Fuel pump coupler

28

CABLE ROUTING SPEC25 Engine oil level switch lead26 Air filter case drain hose27 Air induction system hose28 Ignition coil29 Cover30 Rivet31 Screw32 Coupler33 Main harness34 Frame35 Rear fender

29

A Make sure the headlight lead in the rubber cover.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.D Route the thermo switch lead through the steel

band on the radiator.E Fasten the main harness and thermo switch lead

with a plastic clamp. Insert the plastic clamp intothe hole on the frame.

F Route the ignition coil sub-wire harness under thethrottle position sensor.

G To the carburetor.H Route the coolant reservoir tank breather hose up-

per the air vent surge tank.I Fasten the wire harness and ignition coil subwire

harness with a plastic clamp.J Route the idle adjust cable upper the ground lead.K Fasten the fuel pump lead, speed sensor lead,

neutral switch lead, rear brake light lead, fuel send-er lead, starter motor lead and EXUP cable with aplastic clamp.

CABLE ROUTING SPEC

30

tank breather hose have each white mark.S 30 mm (1.17 in)T Fasten the battery positive lead and starter motor

lead with a plastic locking tie.U Route the rear flasher light lead in the hole on the

rear fender.V Insert the tail /brake light lead and turn signal leads

under the tail /brake light.W Fasten the rear flasher light lead and taillight lead

with a plastic clamp. Route the rear flasher lightlead and taillight lead in the hole on the taillightbracket.

L Fasten the fuel pump lead, speed sensor lead,neutral switch lead, rear brake light lead, fuel send-er lead, starter motor lead and EXUP cable with aplastic clamp.

M 125 mm (4.88 in)N 50 mm (1.95 in)O To the fuel cock.P To the fuel sender.Q Insert the fuel tank over flow hose into a front side

nipple of fuel tank.R Insert the fuel tank breather hose into a back side

nipple of fuel tank. The fuel tank nipple and the fuel

CABLE ROUTING SPEC

31

D At the back side of turning point, battery negativelead is fixed to wire harness.

E Route the fuel tank overflow hose and fuel tankbreather hose in front of the crank case breatherhose and under the fuel hose and front of the EXUPservomotor bracket and upper the EXUP servomotor.

F To the idle adjust screw.G To the engine backward.H Make sure the sidestand switch coupler, engine oil

level sensor coupler, EXUP servo motor couplerand acmagneto coupler in the rubber cover.

X Fasten the main harness with a plastic band on therear fender.

Y Position the ground coupler over the main harness.Z Route the ground lead under the starter relay lead.A Fasten the starter relay lead, ground lead, starting

circuit cutoff relay lead, alam lead and main harnesswith a plastic clamp. Route the clamp end to outside,and insert it between wire harness and fender.

B Route the taillight leads through the rear fender.C Fasten the main harness, battery negative lead

and rear fender with a plastic clamp. Clamp the bat-tery negative lead with a white tape mark.

CABLE ROUTING SPEC

32

should be not exceed just behind 30 mm of all coupler.O 0 30 mmP Although the main switch lead couplers and the han-

dlebar switch lead couplers are the same in shape,they differ in color (the former is white, and the latter,blue). Connect the couplers of the same color.

Q Direct the ignition coil leads upward and insertthem into position at the rubber damper.

R 90S Route the battery negative lead inside the main

harness.T Route the battery positive lead upper the main harness.

I Fasten the main harness with a plastic clamp. In-sert the plastic clamp into the hole on the frame.

J Route the charcoal canister hose under the engineair vent hose, coolant reservoir tank breather hoseand all of leads. (California only)

K Fasten the wire harness with a plastic clamp andthen insert the clamp into the frame.

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 har-ness and fan motor lead with a plastic clamp.

N Route the band end to inside. The clamp position

CABLE ROUTING SPEC

33

PERIODIC MAINTENANCE ANDLUBRICATION INTERVALS

CHKADJ

EB300000

PERIODIC CHECKS AND ADJUSTMENTSINTRODUCTIONThis chapter includes all information necessary to perform recommended checks and adjustments. Iffollowed, these preventive maintenance procedures will ensure more reliable vehicle operation, alonger service life and reduce the need for costly overhaul work. This information applies to vehiclesalready in service as well as to new vehicles that are being prepared for sale. All service techniciansshould be familiar with this entire chapter.EB301000

PERIODIC MAINTENANCE AND LUBRICATION INTERVALS

No ITEM CHECKS AND MAINTENANCE JOBSAfter the

firstEvery Every Annual

No. ITEM CHECKS AND MAINTENANCE JOBS first1,000 km 10,000 km 20,000 km check

1 * Fuel line Check fuel hoses and vacuum hose for cracks or

damage. Replace if necessary.

2 * Fuel filter Check condition. Replace if necessary.

3 Spark plugs Check condition. Clean, regap or replace if necessary.

4 * Valves Check valve clearance. Adjust if necessary. Every 40,000 km

5 Air filter Clean or replace if necessary.

6 Clutch Check operation. Adjust or replace cable.

7 * Front brake Check operation, fluid level and vehicle for fluid leakage. Correct accordingly. Replace brake pads if necessary.

8 * Rear brake Check operation, fluid level and vehicle for fluid leakage. Correct accordingly. Replace brake pads if necessary.

9 * Brake hose Check for cracks or damage. Replace if necessary.

10 * Wheels Check balance, runout and for damage. Rebalance or replace if necessary.

11 * Tires

Check tread depth and for damage. Replace if necessary. Check air pressure. Correct if necessary.

12 * Wheelbearings Check bearing for looseness or damage. Replace if necessary.

13 * Swingarm Check swingarm pivoting point for play. Correct if necessary. Lubricate with lithium soap base grease.

14 Drive chain

Check chain slack. Adjust if necessary. Make sure that the rear wheel is

properly aligned. Clean and lubricate.

Every 1,000 km and after washing themotorcycle or riding in the rain

15 *Steeringbearings

Check bearing play and Steering for roughness. Correct accordingly.

bearings Lubricate with lithium soap base grease. Every 24,000 km

34

PERIODIC MAINTENANCE ANDLUBRICATION INTERVALS

CHKADJ

NOTE:

No ITEM CHECKS AND MAINTENANCE JOBSAfter the

firstEvery Every Annual

No. ITEM CHECKS AND MAINTENANCE JOBS first1,000 km 10,000 km 20,000 km check

16 * Chassisfasteners Make sure that all nuts, bolts and screws are properly

tightened. Tighten if necessary.

17 Sidestand Check operation. Lubricate and repair if necessary.

18 * Sidestandswitch

Check operation. Replace if necessary.

19 * Front fork Check operation and for oil leakage. Correct accordingly.

20 *Rear shockabsorberassembly

Check operation and shock absorber for oil leakage. Replace shock absorber assembly if necessary.

21 *

Rearsuspensionrelay arm andconnecting armpivoting points

Check operation. Correct if necessary.

22 * Carburetors Check engine idling speed, synchronization and

starter operation. Adjust if necessary.

23 Engine oil Check oil level and vehicle for oil leakage. Correct if necessary. Change. (Warm engine before draining.)

24 Engine oilfilter cartridge Replace.

25 *

CoolingsystemCooling

Check coolant level and vehicle for coolant leakage. Correct if necessary.

Coolingsystem Change coolant.

26 *Front and rearbrakeswitches

Check operation. Correct accordingly.

27 Moving partsand cables Lubricate if necessary.

28 * Air inductionsystem

Check the air cut valve and reed valve for damage. Replace the entire air induction system if necessary.

29 * Exhaustsystem

Check the screw clamp for looseness. Tighten if necessary.

30 * Lights, signalsand switches

Check operation. Correct if necessary. Adjust headlight beam if necessary.

* Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service.

The annual checks must be performed once a year unless a 10,000 km or 20,000 km maintenancewas performed in the same year.

The air filter needs more frequent service if you are riding in unusually wet or dusty areas. Hydraulic brake service

Regularly check and, if necessary, correct the brake fluid level. Every two years replace the internal components of the brake master cylinder and caliper, and

change the brake fluid. Replace the brake hoses every four years and if cracked or damaged.

35

COWLINGSCHKADJ

Order Job/Part Qty Remarks

123456789

Removing the cowlingsRider and passenger seatsRear cowlingBottom cowlingFront cowling inner panel (left)Front cowling inner panel (right)Left side cowlingRight side cowlingWindshieldRear view mirrorFront cowling

111111121

Remove the parts in the order listed.Refer to SEATS.

Front installation, reverse the removalprocedure.

5 Nm (0.5 mkg)

EB302020

COWLINGS

36

AIR FILTER CASE AND IGNITION COIL PLATECHKADJ


123456789

1011

Removing the air filter case andignition coil plateRider seat and fuel tankCrankcase breather hoseAir filter case breather hoseAir induction system hoseClamp screwBoltAir filter caseQuick fastenerIgnition coil couplerSpark plug capIgnition coil plate/ ignition coilRubber baffle

111411214

1/21

Remove the parts in the order listed.

Refer to SEATS and FUEL TANK.

Loosen.

Disconnect.

For installation, reverse the removalprocedure.

EB302040

AIR FILTER CASE AND IGNITION COIL PLATE

37


1234

Removing the air induction systemAir induction pipeAir cutoff valveCarburetor joint hoseAir intake hose

4111



4 Nm (0.4 mkg)

ENGINECHKADJ

OVERHAULING THE ENGINEAIR INDUCTION SYSTEM

38

ENGINE ENG


123456789

Removing the engine

Pinch boltRight front mounting boltWasherSpacerLeft front mounting boltWasherSelf-locking nutRear mounting boltSpacer

211122221


Place a suitable stand under the frame andengine.

Loosen.


NOTE:

40 Nm (4.4 mkg)55 Nm (5.5 mkg)

24 Nm (2.4 mkg)

55 Nm (5.5 mkg)

40 Nm (4.0 mkg)

24 Nm (2.4 mkg)

ENGINE

39

ENGINE ENGEB400700

INSTALLING THE ENGINE1. Install:engine assembly

a. Install the spacer 1 to the frame.b. Temporally tighten the right front mounting

bolt 2 , left front mounting bolt 3 , and wash-ers 4 5 .

c. Lubricate the rear mounting bolts 6 7threads with lithium soap base grease.

d. Install the rear mounting bolts 6 7 and selflocking nut 8 9 .

e. Tighten the self locking nut 8 , and then tight-en the self locking nut 9 .

f. Tighten the pinch bolt 10 .g. Tighten the left mounting bolt 3 .h. Tighten the right mouthing bolt 2 .i. Tighten the pinch bolt 11 .

Self locking nut 8 955 Nm (5.5 mkg)

Right front mounting bolt 240 Nm (4.0 mkg)

Left front mounting bolt 340 Nm (4.0 mkg)

Pinch bolts 10 1124 Nm (2.4 mkg)

40


123

Removing the cylinder headEngineIntake and exhaust camshaftsCylinder headCylinder head gasketDowel pin

112

Remove the parts in the order listed.Refer to ENGINE.Refer to CAMSHAFTS.


50 Nm (5.0 mkg)65 Nm (6.5 mkg)

12 Nm (1.2 mkg)

CYLINDER HEAD ENGEB402000

CYLINDER HEAD

41


1234

5

Separating the crankcaseEngineCylinder headPickup coil and pickup coil rotorStator coil assemblyClutch housing and starter clutchidle gearOil /water pump assemblyTiming chainCrankshaft sprocketPinOil /water pump assembly drive chainguideOil /water pump assembly drive chain

1111

1

Remove the parts in the order listed.Refer to ENGINE.Refer to CYLINDER HEAD.Refer to PICKUP COIL.Refer to GENERATOR.

Refer to OIL PAN AND OIL PUMP.Refer to CLUTCH.

10 Nm (1.0 mkg)

10 Nm (1.0 mkg)

CRANKCASE ENG

CRANKCASE

42

Order Job/Part Qty Remarks6

789

10

Oil /water pump assembly drivesprocketWasherPlateLower crankcaseDowel pin

1

1113


10 Nm (1.0 mkg)

10 Nm (1.0 mkg)

CRANKCASE ENG

43

CRANKCASE ENG

NOTE:

NOTE:

EB412743

ASSEMBLING THE CRANKCASE1. Lubricate:crankshaft journal bearings(with the recommended lubricant)

Recommended lubricantEngine oil

2. Apply:sealant(onto the crankcase mating surfaces and thegroove a of the oil baffle plate)

Yamaha bond No. 121590890-85505

Do not allow any sealant to come into contactwith the oil gallery or crankshaft journal bear-ings. Do not apply sealant to within 2 3 mm ofthe crankshaft journal bearings.

3. Install:dowel pin

4. Install:crankshaft journal lower bearings(into the lower crankcase)

Align the projections a on the crankshaft jour-nal lower bearings with the notches b in thelower crankcase.

Install each crankshaft journal lower bearing inits original place.

5. Set the shift drum assembly and transmis-sion gears in the neutral position.

44

CRANKCASE ENG

CAUTION:

NOTE:

6. Install: lower crankcase 1(onto the upper crankcase 2 )

Before tightening the crankcase bolts, makesure that the transmission gears shift cor-rectly when the shift drum assembly isturned by hand.

7. Install:crankcase bolts

Lubricate the bolt threads with engine oil. Install a washer on bolts 1 10 .Tighten each bolt at 15 Nm in the tightening se-quence cast on the crankcase.

Loosen each bolt one time and tighten 15 Nmin the same sequence.

Tighten bolts 1 to 10 45 50 more.Tighten bolts 11 to 28 as shown below.

M9 115 mm bolts: 1 10M8 60 mm bolt: 21M8 50 mm bolt: 22M6 70 mm bolts: 17 , 19 , 25M6 65 mm bolt: 27M6 64 mm bolts: 16 , 24M6 60 mm bolt: 23M6 55 mm bolts: 11 15M6 50 mm bolt: 18M6 45 mm bolts: 20 , 26 , 28

Bolt 1 1015 Nm (1.5 mkg) + 45 50

Bolt 11 15 , 17 20 , 23 , 25 2812 Nm (1.2 mkg)

Bolt 16 , 2414 Nm (1.4 mkg)

Bolt 21 , 2224 Nm (2.4 mkg)

45


1234

Removing the radiatorRider seat and fuel tank

Air filter case and rubber cover

Bottom cowling and side cowlingsDrive sprocket coverCoolant

Coolant reservoir breather hoseCoolant reservoir hoseCoolant reservoirThermo unit coupler

1111

Remove the parts in the order listed.Refer to SEATS and FUEL TANK inchapter 3.Refer to AIR FILTER CASE AND IGNI-TION COIL PLATE in chapter 3.Refer to COWLINGS in chapter 3.Refer to ENGINE in chapter 4.Drain.Refer to CHANGING THE COOLANT inchapter 3.

Disconnect.

20 Nm (2.0 mkg)

23 Nm (2.3 mkg)

9 Nm (0.9 mkg)

10 Nm (1.0 mkg)

4.5 Nm (0.45 mkg)

RADIATOR COOLEB500000

COOLING SYSTEMRADIATOR

46

RADIATOR COOL

Order Job/Part Qty Remarks56789

101112131415

Thermo unitThermostat assembly breather hoseRadiator inlet hoseOil cooler outlet hoseWater pump breather hoseRadiator outlet hoseWater pump inlet pipeRadiator fan motor couplerHorn bracketRadiatorRadiator fan

11111111111

Disconnect.

Disconnect.

Disconnect.


20 Nm (2.0 mkg)

23 Nm (2.3 mkg)

9 Nm (0.9 mkg)

10 Nm (1.0 mkg)

4.5 Nm (0.45 mkg)

47

VIEW 1. (NO FLOW)

VIEW 2. (FLOW)

AIR INDUCTION SYSTEM CARBEAS00507

CARBURETORSAIR INDUCTION SYSTEMAIR INJECTIONThe air induction system burns unburned ex-haust gases by injecting fresh air (secondaryair) into the exhaust port, reducing the emissionof hydrocarbons.When there is negative pressure at the exhaustport, the reed valve opens, allowing secondaryair to flow into the exhaust port. The requiredtemperature for burning the unburned exhaustgases is approximately 600 to 700C.

EAS00508

AIR CUTOFF VALVEThe air cutoff valve is operated by the intake gaspressure through the piston valve diaphragm.Normally, the air cutoff valve is open to allowfresh air to flow into the exhaust port. Duringsudden deceleration (the throttle valve sudden-ly closes), negative pressure is generated andthe air cutoff valve is closed in order to preventafter-burning.Additionally, at high engine speeds and whenthe pressure decreases, the air cutoff valve au-tomatically closes to guard against a loss of per-formance due to self-EGR.(This low-boost close function is the same ason the FZR600 (3HW).)

VIEW 1. (NO FLOW)When decelerating (the throttle closes), thevalve will close.VIEW 2. (FLOW)During normal operation the valve is open.A From the air filterB To the reed valveC To the carburetor joint

48

A To the air cutoff valveB To cylinder #1D To cylinder #2D To cylinder #3E To cylinder #4

1 Reed valve2 Air cleaner3 Air cutoff valve4 Carburetor joint (cylinder #1)


AIR INDUCTION SYSTEM DIAGRAMS

49


CHECKING THE AIR INDUCTION SYSTEM1. Check:hosesLoose connection Connect properly.Cracks/damage Replace.

pipesCracks/damage Replace.

2. Check: fibre reed 1 fibre reed stopper reed valve seatCracks/damage Replace.

3. Measure: fibre reed bending limit aOut of specification Replace the reedvalve.

Fibre reed bending limit0.4 mm

1 Surface plate

4. Check:air cutoff valveCracks/damage Replace.

50


12345678

Removing the front wheel and brakediscs

Brake hose holder (left and right)Brake caliper (left and right)Wheel axle pinch boltFront wheel axleFront wheelCollar (left and right)Oil seal cover (left and right)Brake disc (left and right)

22111222


Place the motorcycle on a suitable standso that the front wheel is elevated.

Loosen.


NOTE:

Refer to INSTALLING THE FRONTWHEEL.

72 Nm (7.2 mkg)

6 Nm (0.6 mkg)

40 Nm (4.0 mkg)

18 Nm (1.8 mkg)

FRONT WHEEL AND BRAKE DISCS CHASEB700002

CHASSISFRONT WHEEL AND BRAKE DISCS

51

FRONT WHEEL AND BRAKE DISCS CHAS

18 Nm (1.8 mkg)NOTE:

72 Nm (7.2 mkg)

23 Nm (2.3 mkg)NOTE:

CAUTION:

40 Nm (4.0 mkg)

WARNING

EB700725

INSTALLING THE FRONT WHEEL1. Lubricate:wheel axleoil seal lips

Recommended lubricantLithium soap base grease

2. Install:brake discs 1

Apply LOCTITE 648 to the threads of thebrake disc bolts.

Tighten the brake disc bolts in stages and in acrisscross pattern.

3. Tighten:wheel axle 1wheel axle pinch bolt 1

When front wheel is installed to front fork, makesure that wheel axle 1 top end side and frontfork end side are align a together. Then, tight-en wheel axle pinch bolt 2 .

Before tightening the wheel axle nut, pushdown hard on the handlebars several timesand check if the front fork rebounds smooth-ly.

4. Install:brake calipers

Make sure that the brake hose is routedproperly.

52


123456789

10

Removing the rear brake mastercylinder and brake fluid reservoirBrake fluidBrake fluid reservoir capBrake fluid reservoir diaphragm holderBrake fluid reservoir diaphragmBrake fluid reservoirBrake fluid reservoir hoseHose jointUnion boltCopper washerBrake hoseBrake master cylinder

1111111211


Drain.


5 Nm (0.5 mkg)

30 Nm (3.0 mkg)

23 Nm (2.3 mkg)

FRONT AND REAR BRAKES CHASEB702202

FRONT AND REAR BRAKESREAR BRAKE MASTER CYLINDER AND BRAKE FLUID RESERVOIR

53

INSTRUMENT FUNCTIONS ELEC

1 Neutral indicator light 2 High beam indicator light 3 Turn signal indicator light 4 Fuel level warning light 5 Oil level warning light

NOTE:

NOTE:

ELECTRICALINSTRUMENT FUNCTIONSINDICATOR LIGHTS

Neutral indicator light This indicator light comes on when the trans-mission is in the neutral position.High beam indicator light This indicator comes on when the headlighthigh beam is used.Turn signal indicator light This indicator light flashes when the turn signalswitch is pushed to the left or right.Fuel level warning light This warning light comes on when the fuel leveldrops below approximately 3.8 L. When this oc-curs, refuel as soon as possible.The electrical circuit of the warning light can bechecked according to the following procedure.1. Set the engine stop switch to and turn

the key to ON.2. Shift the transmission into the neutral posi-

tion or pull the clutch lever.3. Push the start switch. If the warning light

does not come on while pushing the startswitch, have a Yamaha dealer check theelectrical circuit.

This model is equipped with a selfdiagnosis de-vice for the fuel level warning light circuit. Referto SELF-DIAGNOSIS.

Oil level warning light This warning light comes on when the engine oillevel is low.The electrical circuit of the warning light can bechecked according to the following procedure.1. Set the engine stop switch to and turn




Even if the oil level is sufficient, the warning lightmay flicker when riding on a slope or during sud-den acceleration or deceleration, but this is nota malfunction.

54


1 Coolant temperature gauge2 Coolant temperature warning light

CAUTION:

COOLANT TEMPERATURE WARNING LIGHTCoolant temperature warning light This warning light comes on when the engineoverheats. When this occurs, stop the engineimmediately and allow the engine to cool.The electrical circuit of the warning light can bechecked according to the following procedure.1. Set the engine stop switch to and turn




Do not operate the engine if it is overheated.

Coolanttemperature Display Conditions What to do

0 39C Message LO isdisplayed.OK. Go ahead withriding.

40 116C Temperature isdisplayed.OK. Go ahead withriding.

117 139CTemperatureflashes.Warning lightcomes on.

Stop the motorcycle andallow it to idle until thecoolant temperaturegoes down.If the temperature doesnot go down, stop theengine. Refer to OVERHEATING in chapter 9.

Above 140CMessage HIflashes.Warning lightcomes on.

Stop the engine andallow it to cool.Refer to OVERHEATING in chapter 9.

55

1 Speedometer2 Odometer/ tripmeter/ fuel reserve tripmeter/

clock3 RESET button4 SELECT button


NOTE:

SPEEDOMETER UNITThe speedometer unit is equipped with the fol-lowing:a digital speedometer (which shows ridingspeed)

an odometer (which shows the total distancetraveled)

two tripmeters (which show the distancetraveled since they were last set to zero)

a fuel reserve tripmeter (which shows the di-stance traveled on the fuel reserve)

a clockOdometer and tripmeter modesPushing the SELECT button switches the dis-play between the odometer mode ODO andthe tripmeter modes TRIP 1 and TRIP 2 inthe following order:ODO TRIP 1 TRIP 2 ODOIf the fuel level warning light comes on (seepage 3-2), the odometer display will automati-cally change to the fuel reserve tripmeter modeTRIP F and start counting the distance trav-eled from that point. In that case, pushing theSELECT button switches the display betweenthe various tripmeter and odometer modes inthe following order:TRIP F TRIP 1 TRIP 2 ODO TRIP FTo reset a tripmeter, select it by pushing the SE-LECT button, and then push the RESET but-ton. If you do not reset the fuel reserve tripmetermanually, it will reset itself automatically and thedisplay will return to TRIP 1 after refueling andtraveling 5 km.

After resetting the fuel reserve tripmeter, thedisplay will return to TRIP 1, unless a differentmode had been previously selected; in thatcase, the display automatically returns to theprior mode.

56


CAUTION:

0 r /minfor3 seconds

Circuit-specificnumber of r /minfor 2.5 seconds(See the tablebelow.)

Currentenginespeed for3 seconds

Clock modeTo change the display to the clock mode, pushthe SELECT button for at least one second.To change the display back to the odometermodes, push the SELECT button.To set the clock:1. Push the SELECT button and RESET

button together for at least two seconds.2. When the hour digits start flashing, push the

RESET button to set the hours.3. Push the SELECT button, and the minute

digits will start flashing.4. Push the RESET button to set the minutes.5. Push the SELECT button and then release

it to start the clock.Tachometer

The electric tachometer allows the rider to moni-tor the engine speed and keep it within the idealpower range.

Do not operate the engine in the tachometerred zone.Red zone: 11,750 r/min and above

Self-diagnosis devicesThis model is equipped with a self-diagnosis de-vice for the following electrical circuits:Throttle position sensorSpeed sensorEXUP system

If any of those circuits are defective, thetachometer will repeatedly display the followingerror code:

57

ELECTRIC STARTING SYSTEM ELEC


1234

Removing the starter motorRider seatFuel tankLeft side cowlingEXUP servomotorThrottle stop screwStarter motor leadStarter motor assembly

1111

Remove the parts in the order listed.Refer to SEATS in chapter 3.Refer to FUEL TANK in chapter 3.Refer to COWLINGS in chapter 3.


5 Nm (0.5 mkg)

7 Nm (0.7 mkg)

ELECTRIC STARTING SYSTEMSTARTER MOTOR

58


123456789

Disassembling the starter motorStarter motor rear coverBearingStarter motor yokeO-ringArmature assemblyBrushBrush holderStarter motor front coverBearing

111212111

Disassembly the parts in the order listed.

For assembly, reverse the disassemblyprocedure

5 Nm (0.5 mkg)

ELECTRIC STARTING SYSTEM ELECEB803501

59


NOTE:

EB803511

Checking The Starter Motor1. Check:commutatorDirt Clean with 600 grit sandpaper.

2. Measure:commutator diameter aOut of specification Replace the startermotor.

Min. commutator diameter23.5 mm

3. Measure:mica undercut aOut of specification Scrape the mica to theproper measurement with a hacksaw bladewhich has been grounded to fit the commuta-tor.

Mica undercut1.5 mm

The mica must be undercut to ensure proper op-eration of the commutator.

4. Measure:armature assembly resistances (commuta-tor and insulation)Out of specification Replace the startermotor.

a. Measure the armature assembly resistanceswith the pocket tester.

Pocket tester90890-03112

Armature assemblyCommutator resistance 1

Continuity OKNO continuity NG

Insulation resistance 2Above 1 M at 20C

b. If any resistance is out of specification, re-place the starter motor.

60


NOTE:

5. Measure:brush length aOut of specification Replace the brushesas a set.

Min. brush length3.65 mm

6. Measure:brush spring forceOut of specification Replace the brushsprings as a set.

Brush spring force5.28 7.92 N

7. Check:gear teethDamage/wear Replace the gear.

8. Check:bearingoil sealDamage/wear Replace the defectivepart(-s).

EB803701

Assembling The Starter Motor1. Install:brush seat 1

Align the tab a on the brush seat with the slot bin the starter motor front cover.

2. Install:armature 1

61


5 Nm (0.5 mkg)NOTE:

3. Install:starter motor yoke 2O-rings 1 Newstarter motor rear cover 3bolts

Align the match marks a on the starter motoryoke with the match marks b on the front andrear covers.

62

COOLING SYSTEM ELEC

1 Main switch5 Battery6 Main fuse22 Thermo unit28 Combination meter48 Radiator fan motor49 Radiator fan motor relay50 Radiator fan motor fuse

EB807000

COOLING SYSTEMCIRCUIT DIAGRAM

63

Replace the fuse(-s).

NO

1. Main, signal system and radiator fanmotor fuses

Check the main, signal system, and radiatorfan motor fuses for continuity.Refer to CHECKING THE FUSES in chap-ter 3.

Are the main, signal system, and radiator fanmotor fuses OK?

YES

YES

Clean the batteryterminals.

Recharge or re-place the battery.

NO

Is the battery OK?

Open-circuit voltage12.8 V or more at 20C

2. BatteryCheck the condition of the battery.Refer to CHECKING AND CHARGINGTHE BATTERY in chapter 3.

Replace the mainswitch.

NO

EB802411

3. Main switchCheck the main switch for continuity.Refer to CHECKING THE SWITCHES.

Is the main switch OK?

YES

NO

EB807400

4. Radiator fan motorDisconnect the radiator fan motor couplerfrom the wire harness.

Connect the battery (12 V) as shown.

YES

The radiator fan mo-tor is faulty and mustbe replaced.

Battery positive lead blue Battery negative lead black

12

Does the radiator fan motor turn?

COOLING SYSTEM ELEC

CAUTION:

NOTE:

EB807010 EB802401

TROUBLESHOOTINGThe radiator fan motor fails to turn.The coolant temperature meter needlefails to move when the engine is warm.

If the engine is kept running at over 1,500rpm for at least one minute with the switchremaining placed in neutral position andthe throttle valve fully open, even when thecoolant temperature is low enough, the ra-diator fan motor will start rotating. This,however, is not trouble.

Keep hands and other body regions awayto avoid injury.

Check:1. main, signal system, and radiator fan motor

fuses2. battery3. main switch4. radiator fan motor5. Fan motor relay6. Speedometer7. Thermo unit8. Wiring

(the entire cooling system)

Before troubleshooting, remove the followingpart(-s).

1) rider seat2) bottom cowling3) front cowling inner panels4) left side cowling5) windshieldTroubleshooting with the following specialtool(-s).


EB802400

64

NO

EB807400

5. Fan motor relayDisconnect the fan motor relay coupler.Connect the pocket tester ( 1) and bat-tery (12V) to the fan motor relay coupler asshown.

YES

Replace the fan mo-tor relay.

Battery positive lead brown Battery negative lead green/black Tester positive prove brown Tester negative prove blue

12

Does the radiator fan motor relay have conti-nuity between brown and blue?

34

The speedometer isfaulty and must be re-paired.

NO

6. SpeedometerDisconnect the thermo unit coupler.Set the main switch to ON.Connect the green/red and black/blue terminals with a jumper lead as shown.

YES

Does the coolant temperature display HIand warning light comes on?

13

2

Remove the thermo unit from the radiator.Connect the pocket tester ( 1) to the ther-mo unit as shown.

Immerse the thermo unit in a container filledwith coolant .

Make sure that the thermo unit terminals donot get wet.

Place a thermometer in the coolant.Slowly heat the coolant, then let it cool to thespecified temperature as indicated in thetable.

Check the thermo unit for continuity at thetemperatures indicated in the table.

7. Thermo unit

NOTE:

1

2

3

EB807400

EB807402

Thermo unit9.7 11.4 k at 50C3.4 4.0 k at 80C1.6 1.9 k at 105C1.1 1.2 k at 120C

Handle the thermo unit with special care.Never subject the thermo unit to strongshocks. If the thermo unit is dropped, re-place it.

WARNING

Thermo unit23 Nm (2.3 mkg)Three bond sealock 10

COOLING SYSTEM ELEC

65

Replace the thermounit.

NOYES

Does the thermo unit operate properly as de-scribed above?

Properly connect orrepair the coolingsystems wiring.

NO

EB807403

8. WiringCheck the entire cooling systems wiring.Refer to CIRCUIT DIAGRAM.

Is the cooling systems wiring properly con-nected and without defects?

YES

This circuit is OK.

COOLING SYSTEM ELEC

66

SELF-DIAGNOSIS ELEC

0 r /min ... 3 secondsCondition code ... 2.5 secondsEngine speed ... 3 seconds

123

Revolution( 103 r /min) Tachometer display

Time (seconds)

Engine speed

EB812000

SELF-DIAGNOSISThe YZF-R1 features a self-diagnosing system for the following circuit(-s): throttle position sensorEXUPspeed sensor fuel level warning light

If any of these circuits are defective, their respective condition codes will be displayed on the tachome-ter when the main switch is set to ON (irrespective of whether the engine is running or not)

Circuit Defect(-s) System response Condition codeThrottle posi-tion sensor

DisconnectedShort-circuitLocked

The ignitor unit stays set to thewide-open throttle ignition timing.The motorcycle can be ridden.

The tachometer displays thecondition code.

3,000 r/min

EXUP Improper connec-tion

Short-circuit

The EXUP valve stays in the openposition for three seconds andthen the servomotor shuts off. Themotorcycle can be ridden.


7,000 r/min

Servomotor islocked.

The servomotors power supply isconstantly interrupted so that itwill not burn out. The motorcyclecan be ridden.


Speed sensor DisconnectedShort-circuit


4000 r/min

Fuel levelwarning light

Improper connec-tion

Short-circuit

Display the condition code on thefuel level warning light.

The warning lightwill flash eighttimes, then go offfor three seconds.

Tachometer display sequence

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

67

Repair or replace thewire harness.

NO

2. Speed sensorPlace the motorcycle on a suitable stand sothat the rear wheel is elecated.

Connect the pocket tester (DC 20V) to thespeed sensor connector.

YES

Replace the speedsensor.

Replace the ignitorunit.

1. Speed sensorCIRCUIT DIAGRAM

NO

1. Wire harnessCheck the wire harness for continuity.Refer to CIRCUIT DIAGRAM.

Is the wire harness OK?

YES

16 Ignitor unit21 Speed sensor

Tester (+) lead White terminalTester () lead Body earth

1

Set the main switch to ON.Turn the rear wheel slowly.Check the tester voltage (0V - 5V - 0V). Is the speed sensor OK?

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

SELF-DIAGNOSIS ELEC

NOTE:

EB812010

TROUBLESHOOTINGThe tachometer starts to display the self-diagnosis sequence.

Check:1. speed sensor2. fuel level warning light

Troubleshoot with the following specialtool(-s).


COLOR CODEB black. . . . . Br brown. . . . Ch chocolate. . . Dg dark green. . . G green. . . . Gy gray. . . L blue. . . . . O orange. . . . P pink. . . . . R red. . . . .

Sb sky blue. . . . W white. . . . Y yellow. . . . . B/L black/blue. . . B/R black/red. . . B/W black/white. . B/Y black/yellow. . . Br/L brown/blue. . Br/R brown/red. . Br/W brown/white.

G/R green/red. . G/W green/white. . G/Y green/yellow. . L/B blue/black. . . L/R blue/red. . . L/W blue/white. . L/Y blue/yellow. . . O/R orange/red. . R/B red/black. . . R/G red/green. .

R/L red/blue. . . R/W red/white. . R/Y red/yellow. . . W/B white/black. . W/G white/green. . W/Y white/yellow. . Y/B yellow/black. . . Y/L yellow/blue. . .

1 Main switch2 Backup fuse (odometer)3 Rectifier / regulator4 Generator5 Battery6 Main fuse7 Starter relay8 Starter motor9 Relay unit10 Starting circuit cutoff relay11 Fuel pump relay12 Fuel pump13 Sidestand switch14 EXUP servomotor15 Throttle position sensor16 Ignition unit17 Ignition coil18 Spark plug19 Pickup coil20 Neutral switch21 Speed sensor22 Thermo unit23 Meter assembly24 Fuel level indicator light25 Oil level warning light26 Neutral indicator light27 Tachometer28 Combination meter29 Coolant temperature meter30 High beam indicator light31 Turn signal indicator light32 Meter light33 Fuel sender34 Left handlebar switch35 Pass switch36 Dimmer switch37 Horn switch38 Horn39 Clutch switch40 Turn signal switch41 Turn signal relay42 Rear turn signal light43 Front turn signal light44 Headlight45 Auxiliary light46 Headlight relay47 Tail /brake light48 Radiator fan motor49 Radiator fan motor relay50 Radiator fan motor fuse51 Headlight fuse52 Signaling system fuse53 CYCLELOCK (option)54 Ignition fuse55 Engine oil level switch56 Rear brake light switch57 Right handlebar switch58 Front brake light switch59 Lights switch60 Engine stop switch61 Start switch

YZF-R1 WIRING DIAGRAM (For EUR)

COLOR CODEB black. . . . . Br brown. . . . Ch chocolate. . . Dg dark green. . . G green. . . . Gy gray. . . L blue. . . . . O orange. . . . P pink. . . . . R red. . . . .

Sb sky blue. . . . W white. . . . Y yellow. . . . . B/L black/blue. . . B/R black/red. . . B/W black/white. . B/Y black/yellow. . . Br/L brown/blue. . Br/R brown/red. . Br/W brown/white.

G/R green/red. . G/W green/white. . G/Y green/yellow. . L/B blue/black. . . L/R blue/red. . . L/W blue/white. . L/Y blue/yellow. . . O/R orange/red. . R/B red/black. . . R/G red/green. .

R/L red/blue. . . R/W red/white. . R/Y red/yellow. . . W/B white/black. . W/G white/green. . W/Y white/yellow. . Y/B yellow/black. . . Y/L yellow/blue. . .

1 Main switch2 Backup fuse (odometer)3 Rectifier / regulator4 Generator5 Battery6 Main fuse7 Starter relay8 Starter motor9 Relay unit10 Starting circuit cutoff relay11 Fuel pump relay12 Fuel pump13 Sidestand switch14 EXUP servomotor15 Throttle position sensor16 Ignition unit17 Ignition coil18 Spark plug19 Pickup coil20 Neutral switch21 Speed sensor22 Thermo unit23 Meter assembly24 Fuel level indicator light25 Oil level warning light26 Neutral indicator light27 Tachometer28 Combination meter29 Coolant temperature meter30 High beam indicator light31 Turn signal indicator light32 Meter light33 Left handlebar switch34 Pass switch35 Dimmer switch36 Horn switch37 Horn38 Clutch switch39 Turn signal switch40 Turn signal relay41 Fuel sender42 Rear turn signal light43 Front turn signal light44 Headlight45 Headlight relay46 Tail /brake light47 Radiator fan motor48 Radiator fan motor relay49 Radiator fan motor fuse50 Headlight fuse51 Signaling system fuse52 Ignition fuse53 Engine oil level switch54 Rear brake light switch55 Right handlebar switch56 Front brake light switch57 Engine stop switch58 Start switch

YZF-R1 WIRING DIAGRAM (For OCE)

SPECIFICATIONSPERIODIC CHECKS & ADJUSTMENTSOVERHAULING THE ENGINECOOLING SYSTEMCARBURETORSCHASSISELECTRICALWIRING DIAGRAM(For EUR)WIRING DIAGRAM(For OCE)

yamaha yzfr1 00 service manual

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