![Yamaha YZF-R1 (2006) [270/426] Crankcase](/img/pdf.png)
Yamaha YZF-R1 (2006) [270/426] Crankcase
![Yamaha YZF-R1 (2006) [270/426] Crankcase](/views2/1121350/page270/bg10e.png)
CRANKCASE
5-67
EAS25550
DISASSEMBLING THE CRANKCASE
1. Place the engine upside down.
2. Remove:
• Crankcase bolts
NOTE:
• Loosen each bolt 1/4 of a turn at a time, in
stages and in a crisscross pattern. After all of
the bolts are fully loosened, remove them.
• Loosen the bolts in decreasing numerical
order (refer to the numbers in the illustration).
• The numbers embossed on the crankcase
indicate the crankcase tightening sequence.
M6 × 50 mm (2.0 in) bolts: “1”, “7”
M6 × 60 mm (2.4 in) bolts: “2”, “3”
M6 × 70 mm (2.8 in) bolts: “4”, “6”, “8”
M6 × 60 mm (2.4 in) bolt and washer: “5”
M6 × 65 mm (2.5 in) bolts: “9”, “10”
M8 × 60 mm (2.4 in) bolts: “11”, “15”
M8 × 50 mm (2.0 in) bolts: “12” – “14”
M8 × 60 mm (2.4 in) bolt: “16” LOCTITE®
M9 × 105 mm (4.1 in) bolts: “17” – “26”
3. Remove:
• Lower crankcase
CAUTION:
ECA13900
Tap on one side of the crankcase with a
soft-face hammer. Tap only on reinforced
portions of the crankcase, not on the
crankcase mating surfaces. Work slowly
and carefully and make sure the crankcase
halves separate evenly.
4. Remove:
• Dowel pins
5. Remove:
• Crankshaft journal lower bearing
(from the lower crankcase)
NOTE:
Identify the position of each crankshaft journal
lower bearing so that it can be reinstalled in its
original place.
EAS25580
CHECKING THE CRANKCASE
1. Thoroughly wash the crankcase halves in a
mild solvent.
2. Thoroughly clean all the gasket surfaces
and crankcase mating surfaces.
3. Check:
• Crankcase
Cracks/damage → Replace.
• Oil delivery passages
Obstruction → Blow out with compressed
air.
EAS4C81014
CHECKING THE BEARING AND OIL SEALS
1. Check:
• Bearings
Clean and lubricate the bearings, then
rotate the inner race with your finger.
Rough movement → Replace.
2. Check:
• Oil seals
Damage/wear → Replace.
EAS25650
ASSEMBLING THE CRANKCASE
1. Lubricate:
• Crankshaft journal bearings
(with the recommended lubricant)
2. Apply:
• Sealant
NOTE:
Do not allow any sealant to come into contact
with the oil gallery or crankshaft journal bear-
ings. Do not apply sealant to within 2–3 mm
(0.08–0.12 in) of the crankshaft journal bear-
ings.
Recommended lubricant
Engine oil
Yamaha bond No. 1215
(Three Bond No.1215®)
90890-85505
Содержание
- Notice 3
- How to use this manual 4
- Symbols 5
- The following symbols are not relevant to every vehicle 5
- The following symbols are used in this manual for easier understanding 5
- Table of contents 7
- General information 9
- Identification 10
- Features 11
- Outline of the fi system the main function of a fuel supply system is to provide fuel to the combustion chamber at the opti mum air fuel ratio in accordance with the engine operating conditions and the atmospheric tempera ture in the conventional carburetor system the air fuel ratio of the mixture that is supplied to the combustion chamber is created by the volume of the intake air and the fuel that is metered by the jet used in the respective carburetor despite the same volume of intake air the fuel volume requirement varies by the engine operating conditions such as acceleration deceleration or operating under a heavy load carburetors that meter the fuel through the use of jets have been provided with various auxiliary devices so that an optimum air fuel ratio can be achieved to accommodate the constant changes in the operating con ditions of the engine as the requirements for the engine to deliver more performance and cleaner exhaust gases increase it becomes necessary to control th 11
- 46 psi accordingly when the energizing signal from the ecu energizes the fuel injector the fuel passage opens caus ing the fuel to be injected into the intake manifold only during the time the passage remain open therefore the longer the length of time the fuel injector is energized injection duration the greater the volume of fuel that is supplied conversely the shorter the length of time the fuel injector is ener gized injection duration the lesser the volume of fuel that is supplied the injection duration and the injection timing are controlled by the ecu signals that are input from the throttle position sensor for throttle valves throttle position sensor for throttle cable pulley crankshaft position sensor intake air pressure sensor intake air temperature sensor coolant temper ature sensor atmospheric pressure sensor cylinder identification sensor lean angle sensor speed sensor and 12
- Features 12
- Fi system the fuel pump delivers fuel to the fuel injector via the fuel filter the pressure regulator maintains the fuel pressure that is applied to the fuel injector at only 324 kpa 3 4 kg c 12
- Sensor enable the ecu to determine the injection duration the injection timing is determined through the signals from the crankshaft position sensor as a result the volume of fuel that is required by the engine can be supplied at all times in accordance with the driving conditions 12
- Features 13
- Features 14
- Features 15
- Ycc t ycc i system outline 15
- Features 16
- Ycc t ycc i control outline 16
- Features 17
- Features 18
- Features 19
- Features 20
- Important information 21
- Important information 22
- Checking the connections 23
- Special tools 24
- Special tools 25
- Special tools 26
- Special tools 27
- Special tools 28
- Specifications 29
- General specifications 30
- Engine specifications 31
- Engine specifications 32
- Engine specifications 33
- Engine specifications 34
- Engine specifications 35
- Engine specifications 36
- Chassis specifications 37
- Chassis specifications 38
- Electrical specifications 39
- Electrical specifications 40
- Tightening torques 41
- Tightening torques 42
- Tightening torques 43
- Tightening torques 44
- Tightening torques 45
- Tightening torques 46
- Tightening torques 47
- Tightening torques 48
- Lubrication points and lubricant types 49
- Lubrication points and lubricant types 50
- Lubrication system chart and diagrams 52
- Lubrication system chart and diagrams 53
- Lubrication system chart and diagrams 55
- Lubrication system chart and diagrams 57
- Lubrication system chart and diagrams 59
- Lubrication system chart and diagrams 60
- Lubrication system chart and diagrams 61
- Lubrication system chart and diagrams 63
- Cooling system diagrams 64
- Cooling system diagrams 65
- Cooling system diagrams 67
- Cable routing 68
- Cable routing 69
- Cable routing 71
- Cable routing 73
- Cable routing 75
- Cable routing 77
- Cable routing 79
- Cable routing 81
- Cable routing 83
- Periodic checks and adjustments 85
- Introduction this chapter includes all information necessary to perform recommended checks and adjustments if followed these preventive maintenance procedures will ensure more reliable vehicle operation a longer service life and reduce the need for costly overhaul work this information applies to vehicles already in service as well as to new vehicles that are being prepared for sale all service technicians should be familiar with this entire chapter periodic maintenance chart for the emission control system 88
- Periodic maintenance 88
- Since these items require special tools data and technical skills have a yamaha dealer perform the service general maintenance and lubrication chart 88
- Periodic maintenance 89
- Air filter this model s air filter is equipped with a disposable oil coated paper element which must not be cleaned with compressed air to avoid damaging it the air filter element needs to be replaced more frequently when riding in unusually wet or dusty areas hydraulic brake service after disassembling the brake master cylinders and calipers always change the fluid regularly check the brake fluid levels and fill the reservoirs as required every two years replace the internal components of the brake master cylinders and calipers and change the brake fluid 90
- From 24000 mi 37000 km or 36 months repeat the maintenance intervals starting from 8000 mi 13000 km or 12 months 90
- Periodic maintenance 90
- Replace the brake hoses every four years and if cracked or damaged 90
- Since these items require special tools data and technical skills have a yamaha dealer perform the service 90
- Engine 91
- Engine 92
- Engine 93
- Engine 94
- Engine 95
- Engine 96
- Engine 97
- Engine 98
- Engine 99
- Engine 100
- Engine 101
- Engine 102
- Engine 103
- Engine 104
- Engine 105
- Engine 106
- Engine 107
- Engine 108
- Chassis 109
- Chassis 110
- Chassis 111
- Chassis 112
- Chassis 113
- Chassis 114
- Chassis 115
- Chassis 116
- Chassis 117
- Chassis 118
- Chassis 119
- Chassis 120
- Chassis 121
- Chassis 122
- Electrical system 123
- Electrical system 124
- Chassis 125
- General chassis 128
- Removing the seat and battery 128
- General chassis 129
- Removing the front cowling and side cowlings 129
- General chassis 130
- Removing the rear fender 130
- General chassis 131
- Removing the air filter case 131
- General chassis 132
- General chassis 133
- General chassis 134
- Front wheel 135
- Removing the front wheel and brake discs 135
- Disassembling the front wheel 136
- Front wheel 136
- Front wheel 137
- Front wheel 138
- Front wheel 139
- Rear wheel 140
- Removing the rear wheel 140
- Rear wheel 141
- Removing the brake disc and rear wheel sprocket 141
- Disassembling the rear wheel 142
- Rear wheel 142
- Rear wheel 143
- Rear wheel 144
- Rear wheel 145
- Front brake 146
- Removing the front brake pads 146
- Front brake 147
- Removing the front brake master cylinder 147
- Disassembling the front brake master cylinder 148
- Front brake 148
- Front brake 149
- Removing the front brake calipers 149
- Disassembling the front brake calipers 150
- Front brake 150
- Front brake 151
- Front brake 152
- Front brake 153
- Front brake 154
- Front brake 155
- Front brake 156
- Front brake 157
- Front brake 158
- Rear brake 159
- Removing the rear brake pads 159
- Rear brake 160
- Removing the rear brake master cylinder 160
- Disassembling the rear brake master cylinder 161
- Rear brake 161
- Rear brake 162
- Removing the rear brake calipers 162
- Disassembling the rear brake calipers 163
- Rear brake 163
- Rear brake 164
- Rear brake 165
- Rear brake 166
- Rear brake 167
- Rear brake 168
- Rear brake 169
- Rear brake 170
- Handlebars 171
- Removing the handlebars 171
- Handlebars 172
- Removing the handlebars 172
- Handlebars 173
- Handlebars 174
- Handlebars 175
- Front fork 176
- Removing the front fork legs 176
- Disassembling the front fork legs 177
- Front fork 177
- Front fork 178
- Front fork 179
- Front fork 180
- Front fork 181
- Front fork 182
- Front fork 183
- Front fork 184
- Removing the lower bracket 185
- Steering head 185
- Removing the lower bracket 186
- Steering head 186
- Steering head 187
- Steering head 188
- Rear shock absorber assembly 189
- Removing the rear shock absorber assembly 189
- Rear shock absorber assembly 190
- Rear shock absorber assembly 191
- Removing the swingarm 192
- Swingarm 192
- Removing the swingarm 193
- Swingarm 193
- Swingarm 194
- Swingarm 195
- Swingarm 196
- Chain drive 197
- Removing the drive chain 197
- Chain drive 198
- Chain drive 199
- Chain drive 200
- Engine 201
- Engine removal 204
- Removing the drive sprocket 204
- Engine removal 205
- Removing the exhaust pipe 205
- Engine removal 206
- Removing the exhaust pipe 206
- Disassembling the exhaust valve pipe 207
- Engine removal 207
- Disconnecting the leads and hoses 208
- Engine removal 208
- Engine removal 209
- Removing the engine 209
- Engine removal 210
- Engine removal 211
- Camshafts 212
- Removing the cylinder head cover 212
- Camshafts 213
- Removing the camshafts 213
- Camshafts 214
- Camshafts 215
- Camshafts 216
- Camshafts 217
- Camshafts 218
- Camshafts 219
- Camshafts 220
- Cylinder head 221
- Removing the cylinder head 221
- Cylinder head 222
- Cylinder head 223
- Removing the valves and valve springs 224
- Valves and valve springs 224
- Removing the valves and valve springs 225
- Valves and valve springs 225
- Valves and valve springs 226
- Valves and valve springs 227
- Valves and valve springs 228
- Valves and valve springs 229
- Valves and valve springs 230
- Valves and valve springs 231
- Valves and valve springs 232
- Generator 233
- Removing the generator 233
- Generator 234
- Removing the generator 234
- Generator 235
- Generator 236
- Removing the starter clutch 237
- Starter clutch 237
- Starter clutch 238
- Starter clutch 239
- Crankshaft position sensor 240
- Removing the crankshaft position sensor 240
- Crankshaft position sensor 241
- Electric starter 242
- Removing the starter motor 242
- Disassembling the starter motor 243
- Electric starter 243
- Electric starter 244
- Electric starter 245
- Electric starter 246
- Clutch 247
- Removing the clutch cover 247
- Clutch 248
- Removing the push lever shaft 248
- Clutch 249
- Removing the clutch 249
- Clutch 250
- Clutch 251
- Clutch 252
- Clutch 253
- Clutch 254
- Clutch 255
- Clutch 256
- Removing the shift shaft and stopper lever 257
- Shift shaft 257
- Shift shaft 258
- Shift shaft 259
- Oil pump 260
- Removing the oil pan and oil pump 260
- Oil pump 261
- Removing the oil pan and oil pump 261
- Disassembling the oil pump 262
- Oil pump 262
- Oil pump 263
- Oil pump 264
- Oil pump 265
- Oil pump 266
- Oil pump 267
- Crankcase 268
- Separating the crankcase 268
- Crankcase 269
- Separating the crankcase 269
- Crankcase 270
- Crankcase 271
- Crankshaft 272
- Removing the connecting rods and pistons 272
- Crankshaft 273
- Removing the crankshaft 273
- Crankshaft 274
- Crankshaft 275
- Crankshaft 276
- Crankshaft 277
- Crankshaft 278
- Crankshaft 279
- Crankshaft 280
- Crankshaft 281
- Crankshaft 282
- Crankshaft 283
- Crankshaft 284
- Crankshaft 285
- Crankshaft 286
- Removing the transmission shift drum assembly and shift forks 287
- Transmission 287
- Removing the transmission shift drum assembly and shift forks 288
- Transmission 288
- Disassembling the main axle assembly 289
- Transmission 289
- Disassembling the drive axle assembly 290
- Transmission 290
- Disassembling the drive axle assembly 291
- Transmission 291
- Transmission 292
- Transmission 293
- Transmission 294
- Transmission 295
- Cooling system 297
- Radiator 298
- Removing the radiator 298
- Radiator 299
- Removing the radiator 299
- Radiator 300
- Oil cooler 301
- Removing the oil cooler 301
- Oil cooler 302
- Removing the thermostat assembly 303
- Thermostat 303
- Disassembling the thermostat assembly 304
- Thermostat 304
- Thermostat 305
- Disassembling the water pump 306
- Water pump 306
- Water pump 307
- Water pump 308
- Fuel system 309
- Fuel tank 310
- Removing the fuel tank 310
- Fuel tank 311
- Fuel tank 312
- Removing the throttle bodies 313
- Throttle bodies 313
- Removing the injectors 314
- Throttle bodies 314
- Throttle bodies 315
- Throttle bodies 316
- Air induction system 318
- Removing the air cut off valve assembly and hoses 318
- Air induction system 319
- Electrical system 321
- Ignition system 324
- Ignition system 325
- Ignition system 326
- Ignition system 327
- Electric starting system 328
- Electric starting system 329
- Electric starting system 330
- Electric starting system 331
- Electric starting system 332
- Electric starting system 333
- Charging system 334
- Charging system 335
- Charging system 336
- Lighting system 338
- Lighting system 339
- Lighting system 340
- Lighting system 341
- Signaling system 342
- Signaling system 343
- Signaling system 344
- Signaling system 345
- Signaling system 346
- Signaling system 347
- Cooling system 348
- Cooling system 349
- Cooling system 350
- Fuel injection system 352
- Fuel injection system 353
- Fuel injection system 354
- Fuel injection system 355
- Fuel injection system 356
- Fuel injection system 357
- Fuel injection system 358
- Fuel injection system 359
- Fuel injection system 360
- Fuel injection system 361
- Fuel injection system 362
- Fuel injection system 363
- Fuel injection system 364
- Fuel injection system 365
- Fuel injection system 366
- Fuel injection system 367
- Fuel injection system 368
- Fuel injection system 369
- Fuel injection system 370
- Fuel injection system 371
- Fuel injection system 372
- Fuel injection system 373
- Fuel injection system 374
- Fuel injection system 375
- Fuel injection system 376
- Fuel injection system 377
- Fuel injection system 378
- Fuel injection system 379
- Fuel injection system 380
- Fuel injection system 381
- Fuel injection system 382
- Fuel injection system 383
- Fuel injection system 384
- Fuel injection system 385
- Fuel injection system 386
- Fuel injection system 387
- Fuel pump system 388
- Fuel pump system 389
- Fuel pump system 390
- Fuel pump system 391
- Electrical components 392
- Electrical components 393
- Electrical components 395
- Electrical components 397
- Electrical components 398
- Electrical components 399
- Electrical components 400
- Electrical components 401
- Electrical components 402
- Electrical components 403
- Electrical components 404
- Electrical components 405
- Electrical components 406
- Electrical components 407
- Electrical components 408
- Electrical components 409
- Electrical components 410
- Electrical components 411
- Electrical components 412
- Electrical components 413
- Electrical components 414
- Electrical components 415
- Troubleshooting 417
- Troubleshooting 418
- Troubleshooting 419
- Troubleshooting 420
- Troubleshooting 421
- Color code 422
- Wiring diagram 422
- Yzfr1w yzfr1wc 422
- 72 84 83 425
- Sub wire harness 2 sub wire harness 1 wire harness 425
- Wire harness 425
- Wiring diagram 425
- Yzfr1w yzfr1wc wiring diagram 425
- Yzfr1w yzfr1wc wiring diagram 426
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