Related Manuals for Yamaha YZF-R1V
Summary of Contents for Yamaha YZF-R1V
- Page 1 YZF-R1V YZF-R1VC YZF-R1LEV YZF-R1LEVC SUPPLEMENTARY SERVICE MANUAL LIT-11616-19-75 5VY-28197-11...
- Page 3 FOREWORD This Supplementary Service Manual has been prepared to introduce new service and data for the YZF-R1V/YZF-R1VC/YZF-R1LEV/YZF-R1LEVC. For complete service information procedures it is necessary to use this Supplementary Service Manual together with the following manual. YZF-R1S/YZF-R1SC SERVICE MANUAL: LIT-11616-17-55 (5VY-28197-10)
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Page 4: Important Manual Information
If there is any question about a service procedure, it is imperative that you contact a Yamaha dealer for any service information changes that apply to this model. This policy is intended to provide the customer with the most satisfaction from his vehicle and to conform to federal environmental quality objectives. -
Page 5: How To Use This Manual
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. The manual is divided into chapters. - Page 6 EAS00008 SYMBOLS The following symbols are not relevant to every vehicle. Symbols indicate the subject of each chapter. General information Specifications Periodic checks and adjustments Chassis Engine Cooling system Fuel injection system Electrical system Troubleshooting Symbols indicate the following. Serviceable with engine mounted Filling fluid Lubricant Special tool...
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Page 7: Table Of Contents
CONTENTS GENERAL INFORMATION SPECIAL TOOLS......... SPECIFICATIONS GENERAL SPECIFICATIONS . - Page 8 CHECKING THE PULL LEVER SHAFT AND PULL ROD ..INSTALLING THE CLUTCH ......YZF-R1V/YZF-R1VC/YZF-R1LEV/YZF-R1LEVC 2006 WIRING DIAGRAM...
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Page 9: General Information
SPECIAL TOOLS INFO EAS00027 GENERAL INFORMATION SPECIAL TOOLS 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. -
Page 10: Specifications
SPEC GENERAL SPECIFICATIONS SPECIFICATIONS GENERAL SPECIFICATIONS Item Standard Limit Model code YZF-R1 5VYH (USA), 5VYL (USA) • • • 5VYJ (CAL), 5VYM (CAL) YZF-R1LE 4B14 (USA), 4B15 (CAL) • • • Dimensions Overall length 2,085 mm (82.1 in) • • • Wheelbase 1,415 mm (55.7 in) •... -
Page 11: Engine Specifications
SPEC ENGINE SPECIFICATIONS ENGINE SPECIFICATIONS Item Standard Limit Oil pump Oil-pump-housing-to-inner-and-outer- 0.06 ~ 0.13 mm 0.20 mm rotor clearance (0.0024 ~ 0.0051 in) (0.0079 in) Cylinder head Volume 12.3 ~ 12.9 cm (0.75 ~ 0.79 cu.in) • • • Max. warpage •... -
Page 12: Chassis Specifications
SPEC CHASSIS SPECIFICATIONS CHASSIS SPECIFICATIONS Item Standard Limit Front wheel Wheel type Forged wheel (YZF-R1LE) • • • Rear wheel Wheel type Forged wheel (YZF-R1LE) • • • Front tire Model (manufacturer) Pilot POWER (MICHELIN) (YZF-R1) • • • D218FG (DUNLOP) (YZF-R1) •... - Page 13 SPEC CHASSIS SPECIFICATIONS Item Standard Limit Front brakes Master cylinder inside diameter 16 mm (0.63 in) • • • Caliper cylinder inside diameter 30.2 mm and 27 mm (1.19 in and 1.06 in) • • • Front suspension (YZF-R1) Fork oil Quantity (each front fork leg) 0.52 L (0.46 Imp qt, 0.55 US qt) •...
- Page 14 SPEC CHASSIS SPECIFICATIONS Item Standard Limit Rear suspension (YZF-R1) Spring preload adjusting positions Minimum • • • Standard • • • Maximum • • • (YZF-R1LE) Spring Free length 150.0 mm (5.91 in) • • • Installed length 139.0 mm (5.47 in) •...
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Page 15: Electrical Specifications
SPEC ELECTRICAL SPECIFICATIONS / TIGHTENING TORQUES ELECTRICAL SPECIFICATIONS Item Standard Limit Ignition system T.C.I. unit model (manufacturer) F8T82075 (MITSUBISHI) • • • Battery Manufacturer GS-YUASA • • • Ten hour rate amperage 0.9 A • • • TIGHTENING TORQUES ENGINE TIGHTENING TORQUES Tightening torque Thread Item... -
Page 16: Chassis Tightening Torques
SPEC TIGHTENING TORQUES CHASSIS TIGHTENING TORQUES Tightening Thread Item Remarks size m•kg ft•lb Horn bracket and under bracket Connecting rod assembly (YZF-R1LE) Side cover and fuel tank Front fork and stay (YZF-R1LE) Front fork and bracket (YZF-R1LE) Rear brake master cylinder and foot rest bracket Front brake disc and front wheel (YZF-R1LE) Front wheel axle pinch bolt (YZF-R1LE) See NOTE... -
Page 17: Lubrication Points And Lubricant Types
SPEC LUBRICATION POINTS AND LUBRICANT TYPES EAS00031 LUBRICATION POINTS AND LUBRICANT TYPES ENGINE Lubrication point Lubricant Valve lifter surfaces (intake and exhaust) Valve stem ends (intake and exhaust) EAS00032 CHASSIS Lubrication point Lubricant Pivot shaft... -
Page 18: Lubrication Diagrams
SPEC LUBRICATION DIAGRAMS LUBRICATION DIAGRAMS Main axle Oil delivery pipe Drive axle... -
Page 19: Cable Routing
SPEC CABLE ROUTING EAS00035 CABLE ROUTING Ground lead Insert to the rib of the head Connect after passing over the Meter lead light. (Either location of the right upper side of the duct. Stay 1 and left relays is acceptable.) Clamp the head light lead by Auxiliary light lead (right) The lead should not stretch too... - Page 20 SPEC CABLE ROUTING There should be no slack when clamping. Point the tip of the clamp (excessive part) to the front side of the vehicle. Fasten the head light lead with a clamp. Feed a lead wire through the U shape cutout of the console panel.
- Page 21 SPEC CABLE ROUTING Right handlebar switch lead Route the clutch cable so as to Clamp the leads inside the front Clutch cable get along the front side of the fork of the vehicle. Point the exit Main switch lead main switch after passing it of the horn lead to the left front Left handlebar switch lead through the guide.
- Page 22 SPEC CABLE ROUTING Contact the wire guide to the top face of the under bracket boss. The throttle cable should not be caught between the wire guide and under bracket. The throttle cable (pull side) should be positioned above the vehicle wen the wire guide is installed.
- Page 23 SPEC CABLE ROUTING Wire harness Throttle body lead Clamp the clamp upper end Crankshaft position sensor lead along the line of lower end of Heat protector Clamp it after passing between the hose clamp assembly. Point Right handlebar switch lead the frame and radiator stay.
- Page 24 SPEC CABLE ROUTING The coupler for the air induction Pass the rear brake light switch Clamp the clutch cable so that it solenoid lead and camshaft lead between the swingarm is within this specified clamp. sensor lead should be con- bracket and coolant reservoir To the air filter nected above the ignition coil...
- Page 25 SPEC CABLE ROUTING Heat protector Clamp the leads so that they To the coolant reservoir tank Main switch lead are positioned inner of the vehi- Fold back the clamp and secure Left handlebar switch lead cle than the washer position it after passing the lead through EXUP servo motor lead after routing them between the...
- Page 26 SPEC CABLE ROUTING Clamp the fuel tank drain hose Inner most section of the vehi- Align the molded part of the fuel and fuel tank breather hose. cle. tank drain hose with the stay 1. Route the lead by the inside of Can be routed in any order.
- Page 27 SPEC CABLE ROUTING Heat protector Battery negative lead Throttle body side cap Crankshaft position sensor lead Starter motor lead Mud guard Neutral switch lead A.C.magneto lead Turn signal light lead Ground lead Oil level switch lead License plate light lead Coolant reservoir tank Sidestand switch lead Rear fender rib...
- Page 28 SPEC CABLE ROUTING Pass the wire harness through Point the tip of the clamp Pass the water hose lower side the clamp inserted to the radia- (excessive part) to the inside of of the thermostat, and between tor stay. the vehicle. the ground lead and the neutral To the headlight lead All hoses and leads should be...
- Page 29 SPEC CABLE ROUTING Pass the lead through inside of Make sure to position the cou- Point the tip of the clamp (sur- the battery band. pler at the downmost position of plus section) to the rear side of Press on the tip of the clamp leads.
- Page 30 SPEC CABLE ROUTING Point the tip of the clamp Fasten wire harness, Insert the wire harness wrap- (excessive part) to the down A.C.magneto lead, and throt- ping clamp to the hole of the side of the vehicle. Fasten the tle body lead with a clamp. frame.
- Page 31 SPEC CABLE ROUTING Do not place it beyond pipe 3 Route the leads in random in the direction to the external order. part of the vehicle. Route each lead higher than the frame plate, pass it to the inside of the vehicle from the hole.
- Page 32 SPEC CABLE ROUTING Fuel tank Install the lip of O-ring facing Fuel piping connector attach- O-ring upward. ment directions. (fuel pump Fuel tank drain hose Install the part pointing the side) Always use hands to Fuel tank breather hose white paint part of the hose to connect / disconnect the connec- Clip the left side of the vehicle.
- Page 33 SPEC CABLE ROUTING 2. After Item 1 mentioned above is finished, check that the clamp is inserted from the down side, -sections are perfectly equipped.
- Page 34 SPEC CABLE ROUTING for CAL Insert the hose until it reaches Install the part pointing the Clip the R-bottom of the pipe. white paint mark to the left side Clamp Install the part pointing the of the vehicle. Rivet white paint mark to the front Install the part pointing the yel- Roll over valve assembly side of the vehicle.
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Page 35: Periodic Checks And Adjustments
PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM / GENERAL MAINTENANCE AND LUBRICATION CHART EAS00036 PERIODIC CHECKS AND ADJUSTMENTS 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. - Page 36 27 * switches • Adjust headlight beam. * Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service. NOTE: From 24,000 mi (37,000 km) or 36 months, repeat the maintenance intervals starting from 8,000 mi (13,000 km) or 12 months.
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Page 37: Chassis
ADJUSTING THE FRONT FORK LEGS EAS00155 CHASSIS ADJUSTING THE FRONT FORK LEGS (YZF-R1LE) The following procedure applies to both of the front fork legs. WARNING • Always adjust both front fork legs evenly. Uneven adjustment can result in poor han- dling and loss of stability. - Page 38 ADJUSTING THE FRONT FORK LEGS NOTE: NOTE: To find the standard position, turn the adjusting bolt in direction until it stop. 1. If the alignment mark on the adjusting bolt is positioned past the alignment mark on the front fork cap, turn the adjusting bolt in direction until the alignment marks match.
- Page 39 ADJUSTING THE FRONT FORK LEGS Compression damping CAUTION: Never go beyond the maximum or minimum adjustment positions. 1. Adjust: • compression damping a. Turn the adjusting screw in direction Compression damping is Direction increased (suspension is harder). Compression damping is Direction decreased (suspension is softer).
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Page 40: Adjusting The Rear Shock Absorber Assembly
ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY EAS00158 ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY (YZF-R1LE) WARNING Securely support the vehicle so that there is no danger of it falling over. Spring preload CAUTION: Never go beyond the maximum or minimum adjustment positions. 1. - Page 41 ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY 1. Adjust: • rebound damping a. Turn the adjusting screw in direction Rebound damping is Direction increased (suspension is harder). Rebound damping is Direction decreased (suspension is softer). Adjusting positions Minimum: 18 clicks in direction Standard: 14 clicks in direction Maximum: 1 clicks in direction * with the adjusting screw fully turned-in...
- Page 42 ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY Compression damping (slow compression damping) CAUTION: Never go beyond the maximum or minimum adjustment positions. 1. Adjust: • slow compression damping a. Turn the adjusting screw in direction Compression damping is Direction increased (suspension is harder).
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Page 43: Chassis
CHAS FRONT WHEEL AND BRAKE DISCS EAS00514 CHASSIS FRONT WHEEL AND BRAKE DISCS (YZF-R1LE) 6 Nm (0.6 m•kg, 4.3 ft•lb) 35 Nm (3.5 m•kg, 25 ft•lb) 6 Nm (0.6 m•kg, 4.3 ft•lb) 91 Nm (9.1 m•kg, 66 ft•lb) 26 Nm (2.6 m•kg, 19 ft•lb) 23 Nm (2.3 m•kg, 17 ft•lb) Order Job/Part... -
Page 44: Rear Wheel And Brake Discs
CHAS REAR WHEEL AND BRAKE DISCS EAS00560 REAR WHEEL AND BRAKE DISCS REAR BRAKE DISC AND REAR WHEEL SPROCKET (YZF-R1LE) 30 Nm (3.0 m•kg, 22 ft•lb) 100 Nm (10 m•kg, 72 ft•lb) Order Job/Part Q’ty Remarks Removing the rear brake disc and Remove the parts in the order listed. - Page 45 CHAS REAR WHEEL AND BRAKE DISCS (YZF-R1LE) Order Job/Part Q’ty Remarks Disassembling the rear wheel Disassemble the parts in the order listed. Collar Bearing Spacer Oil seal Bearing For assembly, reverse the disassembly procedure.
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Page 46: Front Fork
CHAS FRONT FORK EAS00648 FRONT FORK FRONT FORK LEGS (YZF-R1LE) 20 Nm (2.0 m•kg, 14 ft•lb) 25 Nm (2.5 m•kg, 18 ft•lb) 6 Nm (0.6 m•kg, 4.3 ft•lb) 48 Nm (4.8 m•kg, 35 ft•lb) Order Job/Part Q’ty Remarks Disassembling the front fork legs Disassemble the parts in the order listed. - Page 47 CHAS FRONT FORK (YZF-R1LE) 20 Nm (2.0 m•kg, 14 ft•lb) 25 Nm (2.5 m•kg, 18 ft•lb) 6 Nm (0.6 m•kg, 4.3 ft•lb) 48 Nm (4.8 m•kg, 35 ft•lb) Order Job/Part Q’ty Remarks Spring guide Spring seat Dust seal Oil seal clip Oil seal Washer Damper rod assembly...
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Page 48: Disassembling The Front Fork Legs
CHAS FRONT FORK EAS00652 DISASSEMBLING THE FRONT FORK LEGS (YZF-R1LE) The following procedure applies to both of the front fork legs. 1. Remove: • fork stay • fork bracket • cap bolt (from the damper adjusting rod) a. Press down on the spacer with the fork spring compressor b. - Page 49 CHAS FRONT FORK 4. Remove: • dust seal • oil seal clip • oil seal • washer (with a flat-head screwdriver) CAUTION: Do not scratch the inner tube. 5. Remove: • spring seat NOTE: NOTE: Use a wire or the like and bend the end in L- letter shape for about 10 mm (0.39 in) and hook this part to the spring seat end and pull out the spring seat.
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Page 50: Checking The Front Fork Legs
CHAS FRONT FORK EAS00656 CHECKING THE FRONT FORK LEGS (YZF-R1LE) The following procedure applies to both of the front fork legs. 1. Check: • inner tube • outer tube Bends/damage/scratches → Replace. WARNING Do not attempt to straighten a bent inner tube as this may dangerously weaken it. -
Page 51: Assembling The Front Fork Legs
CHAS FRONT FORK EAS00659 ASSEMBLING THE FRONT FORK LEGS (YZF-R1LE) The following procedure applies to both of the front fork legs. WARNING • Make sure the oil levels in both front fork legs are equal. • Uneven oil levels can result in poor han- dling and a loss of stability. - Page 52 CHAS FRONT FORK 4. Install: • dust seal • oil seal clip • oil seal • washer CAUTION: Make sure the numbered side of the oil seal faces up. NOTE: NOTE: • Before installing the oil seal, lubricate its lips with lithium-soap-based grease.
- Page 53 CHAS FRONT FORK 7. Install: • dust seal (with the fork seal driver weight Fork seal driver 90890-01442, YM-01442 8. Install: • rod puller • rod puller attachment (onto the damper rod Rod puller 90890-01437, YM-A8703 Rod puller attachment 90890-01435, YM-A8703 9.
- Page 54 CHAS FRONT FORK 10.Install: • spring seat • spring guide • spacer • clip • fork spring • spring seat (upper) • nut • damper adjusting rod • cap bolt • fork bracket • fork stay a. Install the spring seat, spring guide, spacer and circlip.
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Page 55: Rear Shock Absorber Assembly
CHAS REAR SHOCK ABSORBER ASSEMBLY EAS00685 REAR SHOCK ABSORBER ASSEMBLY (YZF-R1LE) 44 Nm (4.4 m•kg, 32 ft•lb) 92 Nm (9.2 m•kg, 67 ft•lb) 44 Nm (4.4 m•kg, 32 ft•lb) 44 Nm (4.4 m•kg, 32 ft•lb) Order Job/Part Q’ty Remarks Removing the rear shock absorber Remove the parts in the order listed. - Page 56 CHAS REAR SHOCK ABSORBER ASSEMBLY (YZF-R1LE) 44 Nm (4.4 m•kg, 32 ft•lb) 92 Nm (9.2 m•kg, 67 ft•lb) 44 Nm (4.4 m•kg, 32 ft•lb) 44 Nm (4.4 m•kg, 32 ft•lb) Order Job/Part Q’ty Remarks Relay arm For installation, reverse the removal procedure.
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Page 57: Removing The Rear Shock Absorber Assembly
CHAS REAR SHOCK ABSORBER ASSEMBLY EAS00690 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY (YZF-R1LE) 1. Stand the vehicle on a level surface. WARNING Becurely support the vehicle so that there is no danger of it falling over. NOTE: NOTE: Place the vehicle on a suitable stand so that the rear wheel is elevated. -
Page 58: Installing The Rear Shock Absorber Assembly
CHAS REAR SHOCK ABSORBER ASSEMBLY EAS00698 INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY (YZF-R1LE) 1. Lubricate: • spacers • bearings Recommended lubricant Lithium – soap-based grease 2. Check: • connecting rod assembly Refer to “CHECKING THE CONNECTING ROD ASSEMBLY” 3. Install: •... -
Page 59: Swingarm And Drive Chain
CHAS SWINGARM AND DRIVE CHAIN EAS00703 SWINGARM AND DRIVE CHAIN REMOVING THE SWINGARM (YZF-R1LE) 1. Stand the vehicle on a level surface. WARNING Securely support the vehicle so that there is no danger of it falling over. NOTE: NOTE: Place the vehicle on a suitable stand so that the rear wheel is elevated. -
Page 60: Checking The Swingarm
CHAS SWINGARM AND DRIVE CHAIN EAS00707 CHECKING THE SWINGARM (YZF-R1LE) 1. Check: • swingarm Bends/cracks/damage → Replace. 2. Check: • pivot shaft Roll the pivot shaft on a flat surface. Bends → Replace. WARNING Do not attempt to straighten a bent pivot shaft. -
Page 61: Checking The Connecting Rod Assembly
CHAS SWINGARM AND DRIVE CHAIN CHECKING THE CONNECTING ROD ASSEMBLY 1. Check: • connecting rod assembly Bends / damage → Replace the connecting rod assembly • oil seal Damage/wear → Replace • bearing Damage/wear → Replace 2. Measure: • connecting rod assembly length Out of specification →... -
Page 62: Checking The Drive Chain
CHAS SWINGARM AND DRIVE CHAIN EAS00709 CHECKING THE DRIVE CHAIN 1. Measure: • Measure the dimension between 15-links on the inner side and outer side the roller and calculate the dimension between pin centers. • Dimension between pin centers = (Inner dimension + Outer dimension ) / 2... - Page 63 CHAS SWINGARM AND DRIVE CHAIN CAUTION: This vehicle has a drive chain with small rubber O-rings between the drive chain side plates. Never use high-pressure water or air, steam, gasoline, certain solvents (e.g., benzine), or a coarse brush to clean the drive chain.
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Page 64: Engine
ENGINE ENGINE ENGINE 45 Nm (4.5 m•kg, 33 ft•lb) 51 Nm (5.1 m•kg, 37 ft•lb) YZF-R1LE 51 Nm (5.1 m•kg, 37 ft•lb) 45 Nm (4.5 m•kg, 33 ft•lb) 7 Nm (0.7 m•kg, 5.1 ft•lb) Order Job/Part Q’ty Remarks Removing the engine Remove the parts in the order listed. - Page 65 ENGINE 45 Nm (4.5 m•kg, 33 ft•lb) 51 Nm (5.1 m•kg, 37 ft•lb) YZF-R1LE 51 Nm (5.1 m•kg, 37 ft•lb) 45 Nm (4.5 m•kg, 33 ft•lb) 7 Nm (0.7 m•kg, 5.1 ft•lb) Order Job/Part Q’ty Remarks Upper engine mounting bolt Engine mounting adjust bolt NOTE: NOTE:...
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Page 66: Installing The Engine
ENGINE INSTALLING THE ENGINE 1. Install: • engine mounting adjust bolts (temporary tighten) 2. Install: • engine 3. Install: • lower engine mounting bolt • upper engine mounting bolt • self locking nuts NOTE: NOTE: Lubricate the lower and upper engine mount- ing bolts threads with lithium-soap-based grease. - Page 67 ENGINE Pivot shaft wrench 90890-01471, YM-01471 Pivot shaft wrench adapter 90890-01476 7. Tighten: • upper self-locking nut • lower self-locking nut 51 Nm (5.1 m•kg, 37 ft•lb) NOTE: NOTE: First tighten the lower self-locking nut, and then tighten the upper self-locking nut. 8.
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Page 68: Camshafts
ENGINE EAS00196 CAMSHAFTS 10 Nm (1.0 m•kg, 7.2 ft•lb) 10 Nm (1.0 m•kg, 7.2 ft•lb) 24 Nm (2.4m•kg, 17 ft•lb) 24 Nm (2.4 m•kg, 17 ft•lb) 10 Nm (1.0 m•kg, 7.2 ft•lb) Order Job / Part Q’ty Remarks Removing the camshafts Remove the parts in the order listed. -
Page 69: Clutch
CLUTCH CLUTCH CLUTCH COVER 12 Nm (1.2 m•kg, 8.7 ft•lb) 12 Nm (1.2 m•kg, 8.7 ft•lb) 10 Nm (1.0 m•kg, 7.2 ft•lb) Order Job / Part Q’ty Remarks Removing the clutch cover Remove the parts in the order listed. Right side cowling Right frame side cover Right frame side panel Bottom cowling... -
Page 70: Clutch
CLUTCH CLUTCH (YZF-R1) 95 Nm (9.5 m•kg, 69 ft•lb) 10 Nm (1.0 m•kg, 7.2 ft•lb) Order Job / Part Q’ty Remarks Removing the clutch Remove the parts in the order listed. Compression spring Pressure plate Pull rod Bearing Friction plate 1 Clutch plate 1 Friction plate 2 Wire clip... - Page 71 CLUTCH (YZF-R1) 95 Nm (9.5 m•kg, 69 ft•lb) 10 Nm (1.0 m•kg, 7.2 ft•lb) Order Job / Part Q’ty Remarks Clutch boss nut Washer Thrust plate 1 Clutch boss Thrust plate 2 Clutch housing Bearing For installation, reverse the removal procedure.
- Page 72 CLUTCH (YZF-R1LE) 95 Nm (9.5 m•kg, 69 ft•lb) 10 Nm (1.0 m•kg, 7.2 ft•lb) Order Job/Part Q’ty Remarks Removing the clutch Remove the parts in the order listed. Compression spring Pressure plate 1 Pull rod Bearing Friction plate 1 Clutch plate 1 Friction plate 2 Clutch plate 2 Clutch plate 3...
- Page 73 CLUTCH (YZF-R1LE) 95 Nm (9.5 m•kg, 69 ft•lb) 10 Nm (1.0 m•kg, 7.2 ft•lb) Order Job/Part Q’ty Remarks Spring Clutch boss Pressure plate 2 Conical spring washer Thrust plate 2 Clutch housing Bearing For installation, reverse the removal procedure.
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Page 74: Removing The Clutch
CLUTCH EAS00276 REMOVING THE CLUTCH (YZF-R1LE) 1. Remove: • clutch cover • gasket NOTE: 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. -
Page 75: Checking The Friction Plates
CLUTCH 6. Loosen: • clutch boss nut NOTE: NOTE: While holding the clutch boss with the uni- versal clutch holder , loosen the clutch boss nut. Universal clutch holder 90890-04086, YM-91042 7. Remove: • clutch boss nut • springs • clutch boss •... -
Page 76: Checking The Clutch Plates
CLUTCH EAS00281 CHECKING THE CLUTCH PLATES (YZF-R1LE) The following procedure applies to all of the clutch plates. 1. Check: • clutch plate Damage → Replace the clutch plates as a set. 2. Measure: • clutch plate warpage (with a surface plate and thickness gauge Out of specification →... -
Page 77: Checking The Clutch Springs
CLUTCH NOTE: NOTE: When adjusting the clutch assembly width [by replacing the clutch plate(s)], be sure to replace the clutch plate fast. After replacing the clutch plate , if specifica- tions cannot be met, replace the clutch plate EAS00282 CHECKING THE CLUTCH SPRINGS (YZF-R1LE) The following procedure applies to all of the clutch springs. -
Page 78: Checking The Pressur Plate 2
CLUTCH CHECKING THE PRESSUR PLATE 2 (YZF-R1LE) 1. Check: • pressure plate 2 Cracks/damage → Replace. EAS00285 CHECKING THE CLUTCH BOSS (YZF-R1LE) 1. Check: • clutch boss splines Damage/pitting/wear → Replace the clutch boss. NOTE: NOTE: Pitting on the clutch boss splines will cause erratic clutch operation. -
Page 79: Checking The Pull Lever Shaft And Pull Rod
CLUTCH EAS00287 CHECKING THE PULL LEVER SHAFT AND PULL ROD (YZF-R1LE) 1. Check: • pull lever shaft pinion gear teeth • pull rod teeth Damage/wear → Replace the pull rod and pull lever shaft pinion gear as a set. 2. Check: •... - Page 80 CLUTCH 3. Install: • spring • clutch boss nut 95 Nm (9.5 m•kg, 69 ft•lb) NOTE: NOTE: • Put the spring detent into the groove of the pressure plate 2. Assemble so that each spring detent positioned in a different groove. •...
- Page 81 CLUTCH 6. Install: • friction plate 3 • friction plate 2 • clutch plate 3 • clutch plate 2 • clutch plate 1 NOTE: NOTE: Assemble the friction plates and clutch plates according to the installation order. 7. Install: • friction plate 1 NOTE: NOTE: Install the last friction plate shifting half phase.
- Page 82 CLUTCH 10.Install: • pull lever NOTE: NOTE: Install the pull lever with the “ ” mark facing toward upper side. 11.Install: • clutch cover • clutch cover gasket NOTE: NOTE: • Install the pull rod so that the teeth a face towards the rear of the vehicle.
- Page 83 YZF-R1V/YZF-R1VC/YZF-R1LEV/YZF-R1LEVC 2006 WIRING DIAGRAM Main switch Clutch switch A.C. magneto Turn signal switch Rectifier/regulator Horn Fuse (main) Front turn signal/ position light (left) Fuse (backup) Front turn signal/ position light (right) Battery Rear turn signal light (left) Fuse (fuel injection)
- Page 86 YAMAHA MOTOR CO., LTD. 2500 SHINGAI IWATA SHIZUOKA JAPAN...
- Page 87 YZF-R1V/YZF-R1VC/YZF-R1LEV/YZF-R1LEVC R/L R/B G/B 2006 WIRING DIAGRAM O/G R/B O Gy/R Gy/R Dg L/R R/G Y/L B/W G/W Y L/W R/Y Y/R L/B O/B L Gy/G L Br/R W/B Br/R Gy/G Ch B B/R Y/B Sb/W L/R Sb/W Dg Ch B Y/B Br...