![Yamaha YZF-R1 (2002) [7/439] How to use this manual](/img/pdf.png)
Yamaha YZF-R1 (2002) [7/439] How to use this manual
![Yamaha YZF-R1 (2002) [7/439] How to use this manual](/views2/1121352/page7/bg7.png)
EAS00007
HOW TO USE THIS MANUAL
This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive
explanations of all installation, removal, disassembly, assembly, repair and check procedures are
laid out with the individual steps in sequential order.
1
The manual is divided into chapters. An abbreviation and symbol in the upper right corner of
each page indicate the current chapter.
Refer to “SYMBOLS”.
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)
appears.
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
each removal and disassembly section.
5
Numbers are given in the order of the jobs in the exploded diagram. A circled number indicates a
disassembly step.
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 of
parts, notes in jobs, etc.
8
Jobs requiring more information (such as special tools and technical data) are described sequen-
tially.
12
4
5
7
8
3
6
Содержание
- Yzf r1 service manual 3
- Caution 6
- Important manual information 6
- Notice 6
- Warning 6
- How to use this manual 7
- Chk adj 8
- Gen info 8
- Symbols 8
- Trbl shtg 8
- Table of contents 10
- Chapter 1 general information 11
- Chapter 2 specifications 11
- Chapter 3 periodic checks and adjustments 12
- Chapter 4 chassis 14
- Chapter 5 overhauling the engine 15
- Chapter 6 cooling system 18
- Chapter 7 fuel injection system 18
- Chapter 8 electrical 19
- Chapter 9 troubleshooting 20
- Gen info 22
- General information 22
- Motorcycle identification 22
- Features 23
- Gen info 23
- Outline of 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 com bustion chamber is created by the volume of the intake air and the fuel that is metered by the jet that is used in the respective chamber 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 23
- 40 psi higher than the intake manifold pressure accordingly when the energizing signal from the ecu energizes the injector the fuel passage opens causing the fuel to be injected into the intake manifold only during the time the passage remains open therefore the longer the length of time the injector is energized injection duration the greater the volume of fuel that is supplied conversely the shorter the length of time the injector is energized injection duration the lesser the volume of fuel that is sup plied 24
- Features 24
- Fi system the fuel pump delivers fuel to the injector via the fuel filter the pressure regulator maintains the fuel pressure that is applied to the injector at only 284 kpa 2 4 kg c 24
- Gen info 24
- Illustration is for reference only 24
- The injection duration and the injection timing are controlled by the ecu signals that are input from the throttle position sensor crankshaft position sensor intake air pressure sensor atmospheric pressure sensor intake temperature sensor and coolant temperature sensor enable the ecu to determine the injection duration the injection timing is determined through the signals from the crankshaft position sensor and the cylinder identification 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 24
- Features 25
- Gen info 25
- Components ecu electronic control unit the ecu is mounted underneath the seat the main functions of the ecu are ignition control fuel control self diagnosis and load control ecu s internal construction and functions the main components and functions of the ecu can be broadly divided into the following four items a power supply circuit the power supply circuit obtains power from the battery 12 v to supply the power 5 v that is required for operating the ecu b input interface circuits the input interface circuits convert the signals output by all the sensors into digital signals which can be processed by the cpu and input them into the cpu c cpu central processing unit the cpu determines the condition of the sensors in accordance with the level of the signal that is output by the respective sensor then the signals are temporarily stored on the ram in the cpu based on those stored signals and the basic processing program on the rom the cpu calculates the fuel injection duration injection 26
- Features 26
- Gen info 26
- Features 27
- Gen info 27
- Features 28
- Gen info 28
- Features 29
- Gen info 29
- Pressure regulator it regulates the fuel pressure that is applied to the injectors that are provided in the cylinders in order to maintain a constant pressure difference with the pressure in the intake manifold the fuel that is delivered by the fuel pump fills the fuel chamber through the fuel inlet of the regulator and exerts pressure on the diaphragm in the direction for opening the valve a spring that is provided in the spring chamber exerts pressure on the diaphragm in the direction for closing the valve in contrast to the pressure of the fuel thus the valve cannot open unless the fuel pressure overcomes the spring force an intake vacuum is applied to the spring chamber via a pipe when the pressure of the fuel exceeds the sum of the intake vacuum and the spring force the valve that is integrated with the diaphragm opens allowing the fuel to return from the fuel outlet to the fuel tank via the fuel return hose as a result because the intake vacuum fluctuates in accordance with the c 29
- Features 30
- Fuel injector upon receiving injection signals from the ecu the fuel injector injects fuel in the normal state the core is pressed downward by the force of the spring as illustrated the plunger that is integrated with the bottom of the core keeps the fuel passage closed when the current flows to the coil in accordance with the signal from the ecu the core is drawn upward allowing the flange that is integrated with the plunger to move to the spacer since the dis tance of the movement of the needle is thus kept constant the opening area of the fuel passage also becomes constant because the pressure difference of the fuel to the intake manifold pressure is kept constant by the pressure regulator the fuel volume varies in proportion to the length of time the coil is energized the injector that has been recently adopted has a four hole type injection ori fice that enhances the atomization of fuel and improves combustion efficiency 30
- Gen info 30
- Features 31
- Gen info 31
- Features 32
- Gen info 32
- Features 33
- Gen info 33
- Throttle position sensor the throttle position sensor measures the intake air volume by detecting the position of the throttle valve it detects the mechanical angle of the throttle valve through the positional relationship between the moving contact that moves in unison with the throttle shaft and the resistor board in actual operation the ecu supplies 5 v power to both ends of the resistor board and the voltage that is output by the throttle position sensor is used to determine the angle of the throttle valve 33
- Features 34
- Gen info 34
- Intake air pressure sensor and atmospheric pressure sensor intake air pressure sensor the intake air pressure sensor is used for measuring the intake air volume the intake air volume of every intake stroke is proportionate to the intake air pressure therefore the intake air volume can be measured by measuring the intake air pressure the intake air pressure sensor converts the measured intake air pressure into electrical signals and sends those signals to the ecu when the intake air pressure is introduced into the sensor unit which contains a vacuum chamber on one side of the silicon diaphragm the silicon chip that is mounted on the silicon diaphragm con verts the intake air pressure into electrical signals then an integrated circuit ic amplifies and adjusts the signals and makes temperature compensations in order to generate electrical signals that are proportionate to the pressure atmospheric pressure sensor the atmospheric pressure sensor is used for making compensations to the chang 34
- Coolant temperature sensor the signals from the coolant temperature sensor are used primarily for making fuel volume compen sations during starting and warm up the coolant temperature sensor converts the temperature of the coolant into electrical signals and sends them to the ecu this sensor uses a semi conductor thermistor that has a large resistance at low temperatures and a small resistance at high temperatures the thermistor converts the temperature dependent changes in resistance into electrical resistance values which are then input into the ecu 35
- Features 35
- Gen info 35
- Intake temperature sensor the intake temperature sensor corrects the deviation of the air fuel mixture that is associated with the changes in the intake air density which are created by the changes in the intake air temperature that occur due to atmospheric temperatures this sensor uses a semi conductor thermistor that has a large resistance at low temperatures and a small resistance at high temperatures the thermistor converts the temperature dependent changes in resistance into electrical resistance values which are then input into the ecu 35
- Features 36
- Gen info 36
- Detection of intake air volume the intake air volume is detected primarily through the signals from the throttle position sensor and the intake air pressure sensor the intake air volume is determined in accordance with the signals from the atmospheric pressure sensor intake temperature sensor and the engine speed data 37
- Features 37
- Fuel injection system operation and control the fuel injection timing injection duration ignition timing and the coil energizing duration are con trolled by the ecu to determine the basic injection timing the ecu calculates the intake air volume through the signals from the intake air pressure sensor throttle position sensor cylinder identifica tion sensor and crankshaft position sensor furthermore the ecu calculates the final injection timing by adding the following compensations to the aforementioned basic injection duration those obtained from the state of acceleration as well as those based on the signals from various sensors such as the coolant temperature intake tem perature and atmospheric at the same time the ecu assesses the crankshaft position through the signals from the cylinder identification sensor and the crankshaft position sensor then when the ecu determines that it is time to inject fuel it sends an injection command to the injectors further more the ecu also controls 37
- Gen info 37
- Composition of final injection duration 38
- Determining the final injection duration the intake air volume determines the basic injection duration however at a given intake air vol ume the volume of fuel that is required varies by the engine operating conditions such as accelera tion or deceleration or by weather conditions this system uses various sensors to precisely check these conditions applies compensations to the basic injection duration and determines the final injection duration based on the operating condition of the engine 38
- Features 38
- Gen info 38
- Features 39
- Gen info 39
- Features 40
- Gen info 40
- Three way catalytic converter system diagram 40
- Three way catalytic converter system system outline this is a highly efficient exhaust gas cleaning system that effects air fuel control through a joint effort by the fi system and the three way catalytic converter system by effecting comprehensive control of the air fuel ratio in this manner this system reduces the co hc and nox in the exhaust gases the fi system controls the mixture to an optimal air fuel ratio basic air fuel ratio that matches the operating condition of the engine in order to realize an ideal combustion through the joint effort of these control systems the exhaust gas is cleaned in a highly efficient manner without sacrificing engine performance 40
- Features 41
- Gen info 41
- Features 42
- Gen info 42
- Features 43
- Gen info 43
- Gen info 44
- Important information 44
- Caution 45
- Gen info 45
- Important information 45
- Checking the connections 46
- Gen info 46
- Gen info 47
- Special tools 47
- The following special tools are necessary for complete and accurate tune up and assembly use only the appropriate special tools as this will help prevent damage caused by the use of inappropri ate tools or improvised techniques special tools part numbers or both may differ depending on the country when placing an order refer to the list provided below to avoid any mistakes 47
- Tool no tool name function illustration 47
- Gen info 48
- Special tools 48
- Tool no tool name function illustration 48
- Gen info 49
- Special tools 49
- Tool no tool name function illustration 49
- Gen info 50
- Special tools 50
- Tool no tool name function illustration 50
- General specifications 51
- Specifications 51
- Engine 52
- Engine specifications 52
- Engine specifications 53
- Engine specifications 54
- Engine specifications 55
- Engine specifications 56
- Engine specifications 57
- Engine specifications 58
- Engine specifications 59
- Engine specifications 60
- Chassis 61
- Chassis specifications 61
- Chassis specifications 62
- Chassis specifications 63
- Chassis specifications 64
- Electrical 65
- Electrical specifications 65
- Electrical specifications 66
- A nut b bolt 67
- A width across flats b thread diameter 67
- All specification data in this manual are listed in si and metric units use this table to convert metric unit data to imperial unit data 67
- Conversion table 67
- Conversion table tightening torques 67
- General tightening torque specifications this chart specifies tightening torques for stan dard fasteners with a standard iso thread pitch tightening torque specifications for spe cial components or assemblies are provided for each chapter of this manual to avoid warpage tighten multi fastener assemblies in a crisscross pattern and progressive stages until the specified tightening torque is reached unless otherwise specified tightening torque specifications require clean dry threads com ponents should be at room temperature 67
- General tightening torques 67
- Metric multiplier imperial 67
- Mm 0 3937 0 8 in 67
- Mm 0 3937 in 67
- Mm 10 mm 30 3 67
- Mm 12 mm 55 5 67
- Mm 14 mm 85 8 67
- Mm 16 mm 130 13 67
- Mm 6 mm 6 0 67
- Mm 8 mm 15 1 67
- Nm m kg 67
- Tightening torques 67
- Tightening torques 68
- Tightening torques 69
- Tightening torques 70
- Tightening torques 71
- Tightening torques 72
- Lubrication points and lubricant types 73
- Lubrication points and types 73
- Lubrication points and lubricant types 74
- Cooling system diagrams 75
- Cooling system diagrams 76
- Cooling system diagrams 77
- Engine oil lubrication chart 79
- Lubrication diagrams 80
- Lubrication diagrams 81
- Lubrication diagrams 82
- Lubrication diagrams 83
- Lubrication diagrams 84
- Cable routing 85
- Cable routing 86
- Cable routing 87
- Cable routing 88
- Cable routing 89
- Cable routing 90
- Cable routing 91
- Cable routing 92
- Cable routing 93
- Cable routing 94
- Cable routing 95
- For california 95
- Chk adj 96
- General maintenance and lubrication chart 96
- Introduction 96
- Periodic checks and adjustments 96
- Periodic maintenance chart for the emission control system 96
- 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 97
- Chk adj 97
- Engine oil type yamalube 4 20w 40 or engine oil sae 20w 40 api se for temperatures of 5 c 40 f or above yamalube 4 10w 30 or engine oil sae 10w 30 api se for temperatures of 15 c 60 f or below 97
- General maintenance and lubrication chart 97
- 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 replace the brake hoses every four years and if cracked or damaged 97
- Note from 24 000 mi 37 000 km or 36 months repeat the maintenance intervals starting from 4 000 mi 7 000 km or 6 months 97
- Since these items require special tools data and technical skills have a yamaha dealer perform the service 97
- Chk adj 98
- Chk adj 99
- Fuel tank 99
- Caution 100
- Chk adj 100
- Fuel tank 100
- Caution 101
- Chk adj 101
- Fuel tank 101
- Chk adj 102
- Cowlings 102
- Air filter case 103
- Chk adj 103
- Adjusting the valve clearance 104
- Chk adj 104
- Engine 104
- Adjusting the valve clearance 105
- Chk adj 105
- Adjusting the valve clearance 106
- Chk adj 106
- Adjusting the valve clearance 107
- Chk adj 107
- Adjusting the valve clearance 108
- Chk adj 108
- Example valve clearance 0 1 0 0 mm installed is 150 measured clearance is 0 5 mm replace 150 pad with 160 pad 108
- Example valve clearance 0 1 0 7 mm installed is 175 measured clearance is 0 5 mm replace 175 pad with 185 pad 108
- Exhaust 108
- Valve pad selection table intake 108
- Adjusting the valve clearance synchronizing the throttle bodies 109
- Chk adj 109
- Caution 110
- Chk adj 110
- Synchronizing the throttle bodies 110
- Chk adj 111
- Synchronizing the throttle bodies adjusting the engine idling speed 111
- Adjusting the engine idling speed adjusting the throttle cable free play 112
- Chk adj 112
- Adjusting the throttle cable free play 113
- Chk adj 113
- Adjusting the throttle cable free play checking the spark plugs 114
- Caution 114
- Chk adj 114
- Warning 114
- Checking the spark plugs measuring the compression pressure 115
- Chk adj 115
- Caution 116
- Chk adj 116
- Measuring the compression pressure 116
- Chk adj 117
- Measuring the compression pressure 117
- Warning 117
- Chk adj 118
- Measuring the compression pressure checking the engine oil level 118
- Caution 119
- Checking the engine oil level changing the engine oil 119
- Chk adj 119
- Changing the engine oil 120
- Chk adj 120
- A slightly loosen the oil gallery bolt 1 b start the engine and keep it idling until engine oil starts to seep from the oil gallery bolt if no engine oil comes out after one minute turn the engine off so that it will not seize c check the engine oil passages the oil filter cartridge and the oil pump for damage or leakage refer to oil pan and oil pump in chapter 5 d start the engine after solving the problem s and check the engine oil pressure again e tighten the oil gallery bolt to specification 121
- Adjusting the clutch cable free play 1 check clutch cable free play a out of specification adjust 121
- Changing the engine oil adjusting the clutch cable free play 121
- Check engine oil pressure 121
- Chk adj 121
- Clutch cable free play at the pivot bolt of the clutch lever 10 15 mm 0 9 0 9 in 121
- Oil gallery bolt 10 nm 1 m kg 7 ft lb 121
- Adjust clutch cable free play 122
- Adjust clutch mechanism 122
- Adjusting the clutch cable free play 122
- C tighten the locknut d check the clutch cable free play again and adjust it if necessary 122
- Chk adj 122
- Direction a clutch cable free play is increased 122
- Direction b clutch cable free play is decreased 122
- Engine side a loosen the locknut 1 b turn the adjusting nut 2 in direction a or b until the specified clutch cable free play is obtained 122
- Handlebar side a turn the adjusting dial 1 in direction a or b until the specified clutch cable free play is obtained 122
- If the specified clutch cable free play cannot be obtained as described above perform the mechanism adjustment procedure described below 122
- Remove bottom cowling refer to cowlings 122
- Caution 123
- Chk adj 123
- Replacing the air filter element 123
- Caution 124
- Checking the fuel and breather hoses checking the crankcase breather hose 124
- Chk adj 124
- Checking the crankcase breather hose checking the exhaust system 125
- Chk adj 125
- A loosen both locknuts 1 b insert a 4 mm long pin through the notch in the exup valve pulley and into the hole in the exup valve cover c turn both adjusting bolts 2 counterclock wise until there is no exup cable free play d turn both adjusting bolts 1 2 of a turn clock wise e tighten both locknuts and then remove the pin 126
- A turn the main switch on b check that the exup valve operates prop erly 126
- Adjust exup cable free play 126
- Adjusting the exup cables 126
- Adjusting the exup cables 1 remove bottom cowling refer to cowlings 2 remove exup valve pulley cover 1 126
- Check exup cable free play at the exup valve pulley a 126
- Check exup system operation 126
- Chk adj 126
- Exup valve pulley cover bolt 10 nm 1 m kg 7 ft lb 126
- Install exup valve pulley cover 126
- Maximum exup cable free play at the exup valve pulley 1 mm 0 59 in 126
- Adjusting the exup cables checking the coolant level 127
- Caution 127
- Chk adj 127
- Checking the cooling system 128
- Chk adj 128
- Changing the coolant 129
- Chk adj 129
- Warning 129
- Caution 130
- Changing the coolant 130
- Chk adj 130
- Warning 130
- Changing the coolant 131
- Chk adj 131
- Adjusting the front brake 132
- Caution 132
- Chassis 132
- Chk adj 132
- Warning 132
- Adjusting the rear brake 133
- Caution 133
- Chk adj 133
- Warning 133
- Adjusting the rear brake checking the brake fluid level 134
- Caution 134
- Chk adj 134
- Warning 134
- Checking the front and rear brake pads adjusting the rear brake light switch 135
- Chk adj 135
- Checking the front and rear brake hoses bleeding the hydraulic brake system 136
- Chk adj 136
- Warning 136
- Bleeding the hydraulic brake system 137
- Chk adj 137
- Warning 137
- Adjusting the shift pedal adjusting the drive chain slack 138
- Caution 138
- Chk adj 138
- Warning 138
- Adjusting the drive chain slack 139
- Caution 139
- Chk adj 139
- Chk adj 140
- Lubricating the drive chain checking and adjusting the steering head 140
- Warning 140
- Checking and adjusting the steering head 141
- Chk adj 141
- Warning 141
- Checking and adjusting the steering head 142
- Chk adj 142
- Checking and adjusting the steering head checking the front fork 143
- Chk adj 143
- Warning 143
- Adjusting the front fork legs 144
- Caution 144
- Chk adj 144
- Warning 144
- A turn the adjusting screw 1 in direction a or b 145
- Adjust compression damping 145
- Adjust rebound damping 145
- Adjusting positions minimum 26 clicks in direction b standard 13 clicks in direction b maximum 1 click in direction b with the adjusting screw fully turned in direction a 145
- Adjusting the front fork legs 145
- Caution 145
- Chk adj 145
- Compression damping 145
- Direction a rebound damping is increased suspension is harder 145
- Direction b rebound damping is decreased suspension is softer 145
- Never go beyond the maximum or mini mum adjustment positions 145
- Rebound damping 145
- Adjusting the front fork legs adjusting the rear shock absorber assembly 146
- Caution 146
- Chk adj 146
- Warning 146
- A turn the adjusting screw 1 in direction a or b 147
- Adjust rebound damping 147
- Adjusting positions minimum 1 standard 4 maximum 9 147
- Adjusting positions minimum 20 clicks in direction b standard 15 clicks in direction b maximum 1 click in direction b with the adjusting screw fully turned in direction a 147
- Adjusting the rear shock absorber assembly 147
- Caution 147
- Chk adj 147
- Compression damping 147
- Direction a rebound damping is increased suspension is harder 147
- Direction a spring preload is increased suspension is harder 147
- Direction b rebound damping is decreased suspension is softer 147
- Direction b spring preload is decreased suspension is softer 147
- Never go beyond the maximum or mini mum adjustment positions 147
- Rebound damping 147
- Adjusting the rear shock absorber assembly checking the tires 148
- Chk adj 148
- Warning 148
- Checking the tires 149
- Chk adj 149
- Warning 149
- Checking the tires 150
- Chk adj 150
- Warning 150
- Checking the tires checking the wheels 151
- Chk adj 151
- Warning 151
- Chk adj 152
- Warning 152
- Caution 153
- Checking and charging the battery 153
- Chk adj 153
- Electrical system 153
- Warning 153
- Caution 154
- Checking and charging the battery 154
- Chk adj 154
- Caution 155
- Checking and charging the battery 155
- Chk adj 155
- Warning 155
- Charging method using a variable current voltage charger 156
- Checking and charging the battery 156
- Chk adj 156
- Charging method using a constant voltage charger 157
- Checking and charging the battery 157
- Chk adj 157
- Caution 158
- Checking and charging the battery checking the fuses 158
- Chk adj 158
- Checking the fuses 159
- Chk adj 159
- Warning 159
- Caution 160
- Chk adj 160
- Replacing the headlight bulbs 160
- Warning 160
- A turn the adjusting screw 1 in direction a or b 161
- A turn the adjusting screw 2 in direction a or b 161
- Adjust headlight beam horizontally 161
- Adjusting the headlight beam 161
- Adjusting the headlight beam 1 adjust headlight beam vertically 161
- Chk adj 161
- Direction a headlight beam is raised 161
- Direction a headlight beam moves to the right 161
- Direction b headlight beam is low ered 161
- Direction b headlight beam moves to the left 161
- Chassis 162
- Front wheel and brake discs 162
- Front wheel and brake discs 163
- Front wheel and brake discs 164
- Warning 164
- Caution 165
- Front wheel and brake discs 165
- A place the motorcycle on a suitable stand so that the wheel is elevated b before measuring the front brake disc deflection turn the handlebars to the left or right to ensure that the front wheel is sta tionary c remove the brake caliper d hold the dial gauge at a right angle against the brake disc surface e measure the deflection 2 3 mm below the edge of the brake disc 166
- A remove the brake disc b rotate the brake disc by one bolt hole c install the brake disc 166
- Adjust brake disc deflection 166
- Brake disc deflection limit maximum front 0 mm 0 4 in rear 0 5 mm 0 6 in 166
- Brake disc thickness limit minimum front 4 mm 0 8 in rear 4 mm 0 8 in 166
- Checking the brake discs the following procedure applies to all of the brake discs 1 check brake disc damage galling replace 2 measure brake disc deflection out of specification correct the brake disc deflection or replace the brake disc 166
- Front wheel and brake discs 166
- Measure brake disc thickness measure the brake disc thickness at a few different locations out of specification replace 166
- Tighten the brake disc bolts in stages and in a crisscross pattern 166
- Front wheel and brake discs 167
- Front wheel and brake discs 168
- A install a balancing weight 1 onto the rim exactly opposite the heavy spot x 169
- A spin the front wheel b when the front wheel stops put an 169
- A turn the front wheel and make sure it stays at each position shown b if the front wheel does not remain stationary at all of the positions rebalance it 169
- Adjust front wheel static balance 169
- B turn the front wheel 90 so that the heavy spot is positioned as shown c if the heavy spot does not stay in that posi tion install a heavier weight d repeat steps b and c until the front wheel is balanced 169
- Check front wheel static balance 169
- Front wheel and brake discs 169
- Mark at the bottom of the wheel c turn the front wheel 90 so that the 169
- Mark at the bottom of the wheel f repeat steps d through f several times until all the marks come to rest at the same spot g the spot where all the marks come to rest is the front wheel s heavy spot x 169
- Mark is positioned as shown d release the front wheel e when the wheel stops put an 169
- Start with the lightest weight 169
- Rear wheel and brake disc 170
- Rear wheel and brake disc 171
- Rear wheel and brake disc 172
- Rear wheel and brake disc 173
- Warning 173
- Rear wheel and brake disc 174
- A remove the self locking nuts and the rear wheel sprocket b clean the rear wheel drive hub with a clean cloth especially the surfaces that contact the sprocket c install the new rear wheel sprocket 175
- Checking and replacing the rear wheel sprocket 1 check rear wheel sprocket more than 1 4 tooth a wear replace the rear wheel sprocket bent teeth replace the rear wheel sprocket 175
- Installing the rear wheel 1 lubricate wheel axle wheel bearings oil seal lips 175
- Rear wheel and brake disc 175
- Rear wheel sprocket self locking nut 100 nm 10 m kg 72 ft lb 175
- Recommended lubricant lithium soap based grease 175
- Replace rear wheel sprocket 175
- Tighten the self locking nuts in stages and in a crisscross pattern 175
- Caution 176
- Rear wheel and brake disc 176
- Warning 176
- Front and rear brakes 177
- Front and rear brakes 178
- Caution 179
- Front and rear brakes 179
- Warning 179
- Front and rear brakes 180
- Front and rear brakes 181
- Front and rear brakes 182
- Front and rear brakes 183
- Front and rear brakes 184
- Front and rear brakes 185
- Front and rear brakes 186
- Front and rear brakes 187
- Front and rear brakes 188
- Front and rear brakes 189
- Front and rear brakes 190
- Front and rear brakes 191
- Warning 191
- Caution 192
- Front and rear brakes 192
- Warning 192
- Caution 193
- Front and rear brakes 193
- Warning 193
- Front and rear brakes 194
- Front and rear brakes 195
- Front and rear brakes 196
- Front and rear brakes 197
- Front and rear brakes 198
- Front and rear brakes 199
- Warning 199
- A blow compressed air into the brake hose joint opening a to force out the pistons from the brake caliper 200
- B remove the brake caliper piston seals 200
- Before disassembling the brake caliper drain the brake fluid from the entire brake system 200
- Cover the brake caliper piston with a rag be careful not to get injured when the pis tons are expelled from the brake caliper never try to pry out the brake caliper pis tons 200
- Disassembling the rear brake caliper 200
- Front and rear brakes 200
- Put the end of the brake hose into a container and pump out the brake fluid carefully 200
- Remove brake caliper pistons 1 brake caliper piston seals 2 200
- Remove union bolt 1 copper washers 2 brake hose 200
- Warning 200
- Front and rear brakes 201
- Warning 201
- Caution 202
- Front and rear brakes 202
- Warning 202
- Caution 203
- Front and rear brakes 203
- Warning 203
- Caution 204
- Front and rear brakes 204
- Warning 204
- Caution 205
- Front and rear brakes 205
- Warning 205
- Front fork 206
- Front fork 207
- Front fork 208
- Front fork 209
- Warning 209
- Caution 210
- Front fork 210
- Warning 210
- Caution 211
- Front fork 211
- Warning 211
- Caution 212
- Front fork 212
- Warning 212
- Caution 213
- Front fork 213
- Front fork 214
- Front fork 215
- Warning 215
- Front fork 216
- Warning 216
- Handlebars 217
- Handlebars 218
- Handlebars 219
- Warning 219
- Caution 220
- Handlebars 220
- A apply a thin coat of rubber adhesive onto the end of the left handlebar b slide the handlebar grip over the end of the left handlebar c wipe off any excess rubber adhesive with a clean rag 221
- Adjust clutch cable free play refer to adjusting the clutch cable free play in chapter 3 221
- Adjust throttle cable free play refer to adjusting the throttle cable free play in chapter 3 221
- Align the projection a on the left handlebar switch with the hole b in the left handlebar 221
- Clutch cable free play at the end of the clutch lever 10 15 mm 0 9 0 9 in 221
- Do not touch the handlebar grip until the rubber adhesive has fully dried 221
- Handlebars 221
- Install handlebar grip 221
- Install left handlebar switch 1 221
- Throttle cable free play at the flange of the throttle grip 3 5 mm 0 2 0 0 in 221
- Warning 221
- Steering head 222
- Steering head 223
- Steering head 224
- Warning 224
- Caution 225
- Steering head 225
- Rear shock absorber assembly 226
- Rear shock absorber assembly 227
- Warning 227
- Rear shock absorber assembly 228
- Warning 228
- Rear shock absorber assembly 229
- Swingarm and drive chain 230
- Swingarm and drive chain 231
- Swingarm and drive chain 232
- Warning 232
- Swingarm and drive chain 233
- Warning 233
- Swingarm and drive chain 234
- Caution 235
- Swingarm and drive chain 235
- Swingarm and drive chain 236
- Engine 237
- Overhauling the engine 237
- Engine 238
- Engine 239
- Order job part q ty remarks 7 exhaust valve pipe 1 8 muffler 1 for installation reverse the removal procedure 239
- Caution 240
- Engine 240
- Engine 241
- Engine 242
- Engine 243
- Camshaft 244
- Camshaft 245
- Camshaft 246
- Order job part q ty remarks 13 pin 1 14 timing chain guide intake side 1 for installation reverse the removal procedure 246
- Camshaft 247
- Camshaft 248
- Caution 248
- Camshaft 249
- Camshaft 250
- Camshaft 251
- Camshaft 252
- Caution 252
- Camshaft 253
- Warning 253
- Camshaft 254
- Caution 254
- Cylinder head 255
- Order job part q ty remarks removing the cylinder head remove the parts in the order listed engine refer to engine intake and exhaust camshafts refer to camshafts 1 cylinder head 1 2 cylinder head gasket 1 3 dowel pin 2 for installation reverse the removal procedure 255
- Cylinder head 256
- Cylinder head 257
- Valve and valve springs 258
- Valves and valve springs 258
- Valves and valve springs 259
- Valves and valve springs 260
- Valves and valve springs 261
- Valves and valve springs 262
- Valves and valve springs 263
- Caution 264
- Valves and valve springs 264
- Valves and valve springs 265
- Valves and valve springs 266
- Caution 267
- Valves and valve springs 267
- Generator 268
- Generator 269
- Warning 269
- Caution 270
- Generator 270
- Warning 270
- Caution 271
- Do not use a torque wrench to tighten the bolt to the specified angle tighten the bolt until it is at the specified angle 271
- Generator 271
- Install generator rotor cover 271
- Note tighten the generator rotor cover bolts in stages and in a crisscross pattern 271
- Note when using a hexagon bolt note that the angle from one corner to another is 60 271
- Warning 271
- When the bolt are tightened more than the specified angle do not loosen the bolt and then retighten it replace the bolt with a new one and per form the procedure again 271
- Pickup coil 272
- Order job part q ty remarks 7 crankshaft position sensor coupler 1 disconnect 8 crankshaft position sensor 1 9 pickup coil rotor 1 for installation reverse the removal procedure 273
- Pickup coil 273
- Pickup coil 274
- Pickup coil 275
- Clutch 276
- Clutch 277
- Clutch 278
- Clutch 279
- Clutch 280
- Clutch 281
- Clutch 282
- Clutch 283
- Clutch 284
- Shift shaft 285
- Shift shaft 286
- Oil pan and oil pump 287
- Order job part q ty remarks removing the oil pan and oil pump remove the parts in the order listed engine oil drain refer to changing the engine oil in chapter 3 coolant drain refer to changing the coolant in chapter 3 radiator assembly and water pump outlet pipe refer to radiator and oil cooler in chapter 6 exhaust pipe assembly refer to engine 1 oil level switch connector 1 disconnect 2 oil level switch 1 3 oil level switch lead holder 1 4 oil pan 1 5 oil pan gasket 1 6 dowel pin 2 287
- Dowel pin 1 13 oil water pump assembly 1 14 relief valve assembly 1 for installation reverse the removal procedure 288
- Oil pan and oil pump 288
- Order job part q ty remarks 7 drain pipe 1 8 oil strainer 1 9 oil pipe 1 10 oil delivery pipe 1 11 oil water pump assembly drive sprocket cover 1 288
- Oil pan and oil pump 289
- Oil pan and oil pump 290
- Oil pan and oil pump 291
- Oil pan and oil pump 292
- Oil pan and oil pump 293
- Warning 293
- Crankcase 294
- Crankcase 295
- Caution 296
- Crankcase 296
- Crankcase 297
- Crankcase 298
- Caution 299
- Crankcase 299
- Connecting rods and pistons 300
- Caution 301
- Connecting rods and pistons 301
- Connecting rods and pistons 302
- Connecting rods and pistons 303
- Connecting rods and pistons 304
- Connecting rods and pistons 305
- Caution 306
- Connecting rods and pistons 306
- Caution 307
- Connecting rods and pistons 307
- Warning 307
- Connecting rods and pistons 308
- Connecting rods and pistons 309
- Caution 310
- Connecting rods and pistons 310
- Caution 311
- Connecting rods and pistons 311
- Do not use a torque wrench to tighten the nut to the specified angle tighten the nut until it is at the specified angles 311
- E tighten the nut further to reach the speci fied angle 120 311
- Note when using a hexagonal nut note that the angle from one corner to another is 60 311
- Warning 311
- When the nut is tightened more than the specified angle do not loosen the nut and then retighten it replace the bolt with a new one and per form the procedure again 311
- Crankshaft 312
- Caution 313
- Crankshaft 313
- Crankshaft 314
- Crankshaft 315
- Crankshaft 316
- Transmission 317
- Transmission 318
- Transmission 319
- Transmission 320
- Transmission 321
- Transmission 322
- Transmission 323
- Warning 323
- Transmission 324
- Transmission 325
- Cooling system 326
- Radiator 326
- Radiator 327
- Radiator 328
- Radiator 329
- Oil cooler 330
- Oil cooler 331
- Thermostat 332
- Order job part q ty remarks 5 thermostat assembly 1 6 thermostat assembly inlet pipe left 1 for installation reverse the removal procedure 333
- Thermostat 333
- Thermostat 334
- A suspend the thermostat in a container filled with water b slowly heat the water c place a thermometer in the water d while stirring the water observe the ther mostat and thermometer s indicated tem perature 335
- Check thermostat housing cover 1 thermostat housing 2 cracks damage replace 335
- Checking the thermostat 1 check thermostat does not open at 71 85 c 160 185 f replace 335
- If the accuracy of the thermostat is in doubt replace it a faulty thermostat could cause seri ous overheating or overcooling 335
- Thermometer 2 water 3 thermostat 4 container è fully closed é fully open 335
- Thermostat 335
- Caution 336
- Thermostat 336
- Water pump 337
- Water pump 338
- Water pump 339
- Caution 340
- Water pump 340
- Caution 341
- Water pump 341
- Fuel injection system 342
- Fuel injection system 343
- Main switch 5 battery 6 fuse main 7 fuse fuel injection system 0 starting circuit cut off relay a side stand switch c ecu d ignition coil e spark plug f fuel injector h exup servo motor i speed sensor j lean angle cut off switch k cylinder identification sensor l atmospheric pressure sensor m intake air pressure sensor n throttle position sensor o crankshaft position sensor p intake air temperature sensor q coolant temperature sensor r neutral switch b multi function meter s engine stop switch w fuse ignition 343
- Wiring diagram 343
- Fuel injection system 344
- Fuel injection system 345
- Substitute characteristics operation control fail safe action if the ecu detects an abnormal signal from a sensor while the motorcycle is being driven the ecu illuminates the engine trouble warning light and provides the engine with substitute characteristic operation instructions that are appropriate for the type of the malfunction when an abnormal signal is received from a sensor the ecu processes the specified values that are programmed for every sensor in order to provide the engine with substitute characteristics operation instructions that enable the engine to continue to operate or to stop its operation depending on circumstances the ecu takes fail safe actions in two ways one in which the sensor output is set to a prescribed value and the other in which the ecu directly operates an actuator details on the fail safe actions are given in the table below fail safe actions table 345
- Fuel injection system 346
- Troubleshooring chart 346
- Fuel injection system 347
- Diagnostic fault code table 348
- Fuel injection system 348
- Fuel injection system 349
- Diagnostic mode table set the meter display from the regular mode to the diagnosis mode for the setting method refer to diagnostic mode 350
- Fuel injection system 350
- Note check the intake temperature and coolant temperature as close as possible to the area in which the respective sensor is mounted if it is not possible to check it with an atmospheric pressure gauge judge it by using 760 mmhg 29 inhg as the standard if it is not possible to check the intake temperature use the ambient temperature as reference use the compared values for reference 350
- Fuel injection system 351
- Fuel injection system 352
- Fuel injection system 353
- Troubleshooting details this section describes the measures per fault code number displayed on the meter carry out check and maintenance on items or components that could be a cause of malfunction in accordance with the order when the check and maintenance of malfunctioned part is completed restore the meter display according to the restore method fault code no fault code number displayed on the meter when the engine failed to work normally refer to diagnostic fault code table diagnostic code no code number to be used when the diagnostic monitoring mode is operated refer to diag nostic mode 353
- Fuel injection system 354
- Fuel injection system 355
- Fuel injection system 356
- Fuel injection system 357
- Caution 358
- 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
- Throttle bodies 370
- Throttle bodies 371
- Throttle bodies 372
- Throttle bodies 373
- A wash the throttle body in a petroleum based solvent do not use any caustic carburetor cleaning solution b blow out all of passages with compressed air 374
- Caution 374
- Check fuel passages obstruction clean 374
- Checking the injector 1 check injector damage replace 374
- Checking the throttle body 1 check throttle body cracks damage replace the throttle bodies 374
- The throttle bodies should not be disas sembled unnecessarily 374
- Throttle bodies 374
- Throttle bodies 375
- Throttle bodies 376
- A connect the throttle position sensor coupler to the wire harness b connect the digital circuit tester to the throt tle position sensor 377
- Adjust throttle position sensor angle 377
- C measure the throttle position sensor volt age d adjust the throttle position sensor angle so the measured voltage is within the specified range 377
- E after adjusting the throttle position sensor angle tighten the throttle position sensor screws 377
- F while slowly opening the throttle check that the throttle position sensor resistance is within the specified range the resistance does not change or it changes abruptly replace the throttle position sensor the slot is worn or broken replace the throttle position sensor 377
- Note check mainly that the resistance changes gradually when turning the throttle since the readings from closed to wide open throttle may differ slightly from those specified 377
- Tester positive probe blue terminal 1 tester negative probe yellow terminal 2 377
- Throttle bodies 377
- Throttle position sensor resis tance 0 5 1 k ω at 20 c 68 f yellow black 377
- Throttle position sensor voltage 0 3 0 3 v yellow blue 377
- Air induction system 378
- Air induction system 379
- Air induction system diagrams 379
- Air induction system 380
- A remove the ai system solenoid coupler from the wire harness b connect the pocket tester ω 1 to the ai system solenoid terminal as shown 381
- Air induction system 381
- Al system solenoid resistance 18 22 ω at 20 c 68 f 381
- C measure the ai system solenoid resistance 381
- Check al system solenoid 381
- D out of specification replace 381
- Tester positive probe orange 1 tester negative probe green 2 381
- Electrical 382
- Electrical components 382
- Electrical components 383
- Caution 384
- Checking switch continuity 384
- Check each switch for damage or wear proper connections and also for continuity between the ter minals refer to checking switch continuity damage wear repair or replace improperly connected properly connect incorrect continuity reading replace the switch 385
- Checking the switches 385
- Checking the bulbs and bulb sockets 386
- Caution 387
- Checking the bulbs and bulb sockets 387
- Warning 387
- A disconnect the meter assembly coupler meter assembly side b connect two jumper leads 1 from the bat tery terminals to the respective coupler ter minal as shown 388
- A install a good bulb into the bulb socket b connect the pocket tester probes to the respective leads of the bulb socket c check the bulb socket for continuity if any of the readings indicate no continuity replace the bulb socket 388
- A wire that is used as a jumper lead must have at least the same capacity of the bat tery lead otherwise the jumper lead may burn this check is likely to produce sparks therefore make sure no flammable gas or fluid is in the vicinity 388
- C when the jumper leads are connected to the terminals the respective led should illuminate does not light replace the meter assembly 388
- Check each bulb socket for continuity in the same manner as described in the bulb section however note the following 388
- Checking the bulbs and bulb sockets 388
- Checking the condition of the bulb sockets the following procedure applies to all of the bulb sockets 1 check bulb socket for continuity with the pocket tester no continuity replace 388
- Checking the leds the following procedures applies to all of the leds 1 check led for proper operation improper operation replace 388
- Pocket tester ym 03112 388
- Warning 388
- Circuit diagram 389
- Ignition system 389
- Main switch 5 battery 6 fuse main 0 starting circuit cut off relay a side stand switch c ecu d ignition coil e spark plug j lean angle cut off switch o crankshaft position sensor r neutral switch s engine stop switch w fuse ignition 389
- Ignition system 390
- Ignition system 391
- Ignition system 392
- Ignition system 393
- Circuit diagram 394
- Electric starting system 394
- Main switch 5 battery 6 fuse main 8 starter relay 9 starter motor 0 starting circuit cut off relay a side stand switch r neutral switch e clutch switch s engine stop switch t start switch w fuse ignition 394
- Electric starting system 395
- Electric starting system 396
- Warning 396
- Electric starting system 397
- Electric starting system 398
- Electric starting system 399
- Electric starting system 400
- Electric starting system 401
- Electric starting system 402
- Charging system 403
- Circuit diagram 403
- Charging system 404
- Charging system 405
- Circuit diagram 406
- Lighting system 406
- Lighting system 407
- Lighting system 408
- Lighting system 409
- Lighting system 410
- Lighting system 411
- Lighting system 412
- Circuit diagram 413
- Signaling system 413
- Signaling system 414
- Signaling system 415
- Signaling system 416
- Signaling system 417
- Signaling system 418
- Signaling system 419
- Signaling system 420
- Signaling system 421
- C ecu q coolant temperature sensor w fuse ignition 422
- Circuit diagram 422
- Cooling system 422
- Main switch 5 battery 6 fuse main 422
- Z fuse fan motor fan motor relay fan motor 422
- Cooling system 423
- Cooling system 424
- Cooling system 425
- Warning 425
- Circuit diagram 426
- Fuel pump system 426
- Main switch 5 battery 6 fuse main 7 fuse fuel injection 0 starting circuit cut off relay b fuel pump c ecu s engine stop switch w fuse ignition 426
- Fuel pump system 427
- Fuel pump system the ecu includes the control unit for the fuel pump 427
- Fuel pump system 428
- Fuel pump system 429
- Fuel pump system 430
- Warning 430
- Starting failures 431
- Trbl shtg 431
- Troubleshooting 431
- Incorrect engine idling speed 432
- Starting failures incorrect engine idling speed 432
- Trbl shtg 432
- Faulty clutch 433
- Faulty gear shifting 433
- Poor medium and high speed performance 433
- Poor medium and high speed performance faulty gear shifting faulty clutch 433
- Trbl shtg 433
- Overcooling 434
- Overheating 434
- Overheating overcooling poor braking performance 434
- Poor braking performance 434
- Trbl shtg 434
- Faulty front fork legs 435
- Faulty front fork legs unstable handling 435
- Trbl shtg 435
- Unstable handling 435
- Faulty lighting or signaling system 436
- Trbl shtg 436
- Wiring diagram 437
- Yzf r1p yzf r1pc wiring diagram 437
- Color code 438
- Q r s t 438
- Yzf r1p yzf r1pc wiring diagram 438
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Ответы 1
Какая информация содержится в данном руководстве от Yamaha Motor Company, Ltd.?
1 год назад