Yamaha ’09 YZF-R1 Kit Manual
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Yamaha ’09 YZF-R1 Kit Manual

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'09 YZF-R1
KIT MANUAL
The Performance Edge
for excellent riders

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Summary of Contents for Yamaha ’09 YZF-R1

  • Page 1 ’09 YZF-R1 KIT MANUAL The Performance Edge for excellent riders...
  • Page 2 Parts List Symbols • The star mark (*) means that the part is included in the kit set and is a genuine Yamaha part. Therefore, you can easily purchase the part at any Yamaha part dealer when necessary.

  • Page 3: Table Of Contents

    CONTENTS 1 Engine Specifications................... 1 2 Kit Parts ......................2 2-1 Installing Engine Parts................... 2 Maintenance Set (14B-MAINT-70)................ 2 Spark Plug Set (14B-R465B-70)................3 Head-gasket, Cylinder Gasket ................4 High-lift Camshafts....................5 Valve Spring Set (14B-A2110-70)................. 6 Air Funnel Set (MGC-021008-00) ................. 7 Throttle Body Clamp Set (14B-1351A-70) ............

  • Page 4: Engine Specifications

    Engine Specifications Spec Displacement 998cc 998cc Bore/stroke 78.0 x 52.2 mm 78.0 x 52.2 mm Maximum engine speed 13750 rpm 13750 rpm (limiter controlled speed) Compression ratio 12.8:1 12.7:1 (13.2:1 will result from 0.2mm cylinder head surface grinding.) Valve timing (event angle) 110°...

  • Page 5: Kit Parts

    Kit Parts 2-1 Installing Engine Parts Maintenance Set (14B-MAINT-70) Parts List PART No. PART NAME Q’TY REMARKS ° 14B-11181-70 GASKET, t=0.30 mm CYLINDER HEAD 1 14B-11351-00 GASKET, CYLINDER 1 t=0.20mm (STD) 14B-11603-00 PISTON RING SET 5VY-1165A-01 BOLT, CONNECTING ROD SPECIAL 93450-18157 CIRCLIP 3P6-12129-00...

  • Page 6: Spark Plug Set (14B-R465B-70)

    Spark Plug Set (14B-R465B-70) Parts List PART No. PART NAME Q’TY REMARKS 14B-1119C-70 PLUG, SPARK NGK R0465B-10 The spark creating portion of this spark plug is of a semi-surface discharge type of shape. Since these spark plugs have a copper gasket, caution is needed during installation on the following points.

  • Page 7: Head-Gasket, Cylinder Gasket

    Head-gasket, Cylinder Gasket Parts List PART No. PART NAME Q’TY REMARKS 14B-11181-70 GASKET, CYLINDER HEAD 1 t=0.30 mm 14B-11181-80 GASKET, CYLINDER HEAD 1 t=0.35 mm 14B-11351-70 GASKET, CYLINDER 1 t=0.10 mm 14B-11351-80 GASKET, CYLINDER 1 t=0.15 mm These parts are used to adjust the squish height and compression ratio. They should be installed in the direction, which enables the punched alpha-numeral “14B”...

  • Page 8: High-Lift Camshafts

    High-lift Camshafts Parts List PART No. PART NAME Q’TY REMARKS 14B-12170-70 SHAFT, CAM 1 14B-12180-70 SHAFT, CAM 2 This camshaft has a cam profile etc. changed from the STD one. 90105-07006 14B-12176-00 To adjust the valve timing, use the oval holes of the standard cam sprocket. USE THESE OVAL HOLES FOR TIMING ADJUSTMENT.

  • Page 9: Valve Spring Set (14B-A2110-70)

    Valve Spring Set (14B-A2110-70) Parts List PART No. PART NAME Q’TY REMARKS 14B-12113-70 SPRING, 1 I.D.Color:Blue (INT) 14B-12114-70 SPRING, 2 I.D.Color:Red (EXT) This valve spring is used when the camshaft is mounted from the kit. NOTICE When using this valve spring, use the camshafts 14B-12170-70, and 14B-12180-70. –...

  • Page 10: Air Funnel Set (Mgc-021008-00)

    Air Funnel Set (MGC-021008-00) Parts List PART No. PART NAME Q’TY REMARKS PLATE L PLATE R PRIMARY FUNNEL L=55mm SUPPORT L SUPPORT R SHAFT ASSY. Short type Installation 1. Installing the Plate Secure the plate onto the throttle body. As shown, secure the plate only at two positions below, using the supplied screws (25mm long).
  • Page 11 3. Installing the Lever Assembly Secure the lever assembly onto the plates. Using the supplied screws (30mm long), secure the assembly at the locations as shown. Holes for installation 4. Installing the Primary Funnels Secure the primary funnel by screwing it into the plate. •...
  • Page 12 6. Installing the Shaft Assembly Install the shaft assembly that is shorter than the STD. After fitting the assembly onto the ball joint on the motor side, fit the white prism rod on the reverse side to the lever assembly clip. Motor side Clip Ball joint...
  • Page 13 Ycci System Control You can use the Ycci system as the kit funnel. You can control the operation timing by using the YMS software packed together with the kit ECU. You can also control the STD funnel by using the YMS software. This set is made by MG Competition.

  • Page 14: Throttle Body Clamp Set (14B-1351A-70)

    7. Throttle Body Clamp Set (14B-1351A-70) Parts List PART No. PART NAME Q’TY REMARKS CLAMP COMP. Right side (3-4) CLAMP COMP. Left side (1-2) This part is used to enhance maintenance performance of the throttle body. Before using it, cut off the protrusion for positioning bands at the cabjoint.

  • Page 15: Ais-Plug Set (5Vy-A4890-70)

    AIS-plug Set (5VY-A4890-70) This plug set is used when the AIS (Air Induction System), an exhaust gas purifying system, is removed. Parts List PART No. PART NAME Q’TY REMARKS 5SL-1482L-70 PLATE, 2 93608-16M16 PIN, DOWEL 90336-10020 PLUG, TAPER Installation 1. Remove the hose attached to the cylinder head cover and the air cut-off valve accompanying the hose.
  • Page 16 – 13 –...

  • Page 17: Clutch Spring Set (4B1-A6330-70)

    Clutch Spring Set (4B1-A6330-70) Parts List PART No. PART NAME Q’TY REMARKS 4B1-16334-70 SPRING, CLUTCH The kit spring has 10% more installation load than the STD spring. – 14 –...

  • Page 18: Slipper Clutch Setting Set (4C8-A6377-70)

    10. Slipper Clutch Setting Set (4C8-A6377-70) Parts List PART No. PART NAME Q’TY REMARKS ° 4C8-16377-70 NUT, LOCK ° 4B1-16391-70 SHIM Installing this part makes it possible to adjust the engine braking effect. 52.8-53.4mm – 15 –...
  • Page 19 (Recommended setting method) To begin with, the dimensions of the clutch are re-set to the standard values. (For details, please refer to the service manual published from YAMAHA MOTOR CO. LTD. When the slipper clutch setting sets are to be installed, and the number of the SHIMs are to be three in stack, the setting may be carried out according to the standard.
  • Page 20 When installing the kit parts, the back torque limiter tends not to be effective (Engine braking becomes more effective). When decreasing the number of SHIMs (standard setting is three) of slipper clutch setting set, the back torque limiter tends to be effective (Engine braking becomes less effective). Standard effective (Engine braking becomes...

  • Page 21: Transmission Gear

    11. Transmission Gear Parts List PART No. PART NAME Q'TY REMARKS 14B-17401-70-A MAIN AXLE ASSY. 14B-17401-80-C MAIN AXLE ASSY. 14B-15163-00 HSG., BEARING 93306-20652 BRG. 14B-17121-70-A GEAR, 2ND PINION 14B-17121-80-B GEAR, 2ND PINION 14B-17131-AA GEAR, 3RD PINION 14B-17131-AB GEAR, 3RD PINION 14B-17131-AC GEAR, 3RD PINION 14B-17131-BB...
  • Page 22 Parts List PART No. PART NAME Q'TY REMARKS 14B-17261-70-A GEAR, 6TH WHEEL 14B-17261-80-B GEAR, 6TH WHEEL This transmission gear is set at a closer ratio than the STD gear, making it possible to select a gear adapted to the course. Select the gear after referring to the speed table and the ratio table.
  • Page 23 NOTICE This set contains modified gear ratios and docks compared with the STD gearbox. Kit gears cannot use combine standard gear. Gear ratio 38/15 (2.533) 34/14 (2.429) 33/14 (2.357) 37/16 (2.313) 33/16 (2.063) 32/15 (2.133) 32/16 (2.000) 31/16 (1.938) 37/21 (1.762) 31/17 (1.824) 33/19 (1.737) 29/18 (1.611)
  • Page 24 YZF-R1 Mission ratio GEARPLAN Ratio Pinion gear Wheel gear Part number Stamp Part number Stamp number number of teeth of teeth A 2.429 14B-17401-70-A 14B-AB 14B-17211-70-A 14B-1WA B 2.357 14B-17401-70-A 14B-AB 14B-17211-80-B 14B-1WB C 2.313 14B-17401-80-C 14B-C 14B-17211-90-C 14B-1WC 2nd A 2.133 14B-17121-70-A 14B-2PA 14B-17221-70-A 14B-2WA...
  • Page 25 – 22 –...

  • Page 26: Mission Maintenance Set (14B-A7000-70)

    12. Mission Maintenance Set (14B-A7000-70) Parts List PART No. PART NAME Q'TY REMARKS 90387-28003 COLLAR 90209-25011 WASHER 93440-28184 CIRCLIP 90387-25023 COLLAR 90214-25004 WASHER, CLAW 90214-25003 WASHER, CLAW 90387-31003 COLLAR 90209-28008 WASHER 93440-31187 CIRCLIP 90387-28004 COLLAR 90214-29002 WASHER, CLAW 90214-28002 WASHER, CLAW 90387-25008 COLLAR 93102-40330...
  • Page 27 30 32 – 24 –...

  • Page 28: Transmission Assembly

    Transmission Assembly The seal side should face outward (one side seal bearing) and press in the bearing cup all the way into the case until it touches bottom. Apply molybdenum oil to inside of diameter. After assembly, it should rotate smoothly. Apply molybdenum oil to the inside diameter and end.

  • Page 29: Drive Sprockets

    13. Drive Sprockets Parts List PART No. PART NAME Q’TY REMARKS 4XV-17460-75 SPROCKET, DRIVE 15T, 520SIZE 4XV-17460-76 SPROCKET, DRIVE 16T, 520SIZE 4XV-17460-77 SPROCKET, DRIVE 17T, 520SIZE This sprocket is weight-saved by changing the chain size to 520 in relation to the STD one. NOTICE When using this drive sprocket, use the sprocket nut of the kit.

  • Page 30: Sprocket Nut Set (4C8-A7463-70)

    14. Sprocket Nut Set (4C8-A7463-70) Parts List PART No. PART NAME Q’TY REMARKS 4C8-17463-70 90215-30233 WASHER, LOCK This sprocket nut uses a bending type of lock washer instead of the STD caulking type. NOTICE When using this sprocket nut, use the drive sprocket of the kit. –...

  • Page 31: Installing Chassis Parts

    2-2 Installing Chassis Parts 15. Oil Catcher Tank Set (14B-C1707-70) Parts List PART No. PART NAME Q'TY REMARKS 14B-21707-70 OIL TANK COMP. 90467-18172 CLIP 14B-15373-70 PIPE, BREATHER 14B-15393-70 PIPE, BREATHER 2 90480-11006 GROMMET 90387-062N2 COLLAR 90111-06051 BOLT, HEX. SOCKET BUTTON 92907-06200 WASHER, PLAIN The oil catcher tank is available to meet the racing regulations.
  • Page 32 Crankcase Crankcase – 29 –...

  • Page 33: Shock Absorber Rear (14B-22210-70)

    16. Shock Absorber Rear (14B-22210-70) Parts List PART No. PART NAME Q'TY REMARKS 14B-22210-70 SHOCK ABSORBER, Rr. 98 N/mm Rear Suspension Performance Adjustment Method Low-speed compression damping, high-speed compression damping, rebound damping and preload can be adjusted. Low-speed compression damping adjustor (bolt width 4mm, hexagonal hole) Rebound damping...
  • Page 34 Rebound Damping Adjustment Method Turn clockwise to increase the damping force and anticlockwise to reduce the damping force. The adjustment range is between 3 to 20 steps back from the lightly tightened adjustor position. Shipping position: 15 steps back from the tightened adjustor position.

  • Page 35: Spring Rear Shock

    17. Spring Rear Shock Parts List PART No. PART NAME Q'TY REMARKS 14B-22222-70 SPRG., Rr. SHOCK 108 N/mm Identifying stamp: 159.5-55-108 14B-22222-75 SPRG., Rr. SHOCK 103 N/mm Identifying stamp: 159.5-55-103 14B-22222-80 SPRG., Rr. SHOCK 98N/mm Identifying stamp: 159.5-55-98 • These springs can be used with the standard or kit shock absorbers. •...

  • Page 36: Front Fork Assy

    18. Front Fork ASSY Parts List PART No. PART NAME Q'TY REMARKS 14B-23102-70 Fr. FORK ASSY. LH. 10.0 N/mm 14B-23103-70 Fr. FORK ASSY. RH. 10.0 N/mm Front Fork Performance Adjustment Method Designed to develop damping force independent of each other, the left leg develops the compression damping force and the right one the rebound damping force.
  • Page 37 Damping Adjustment Method Turn clockwise to increase the damping force and anticlockwise to reduce the damping force. The adjustment range is: Rebound : 1 to 25 steps back from the adjustor’s clockwise lightly tightened position. Compression : 1 to 25 steps back from the adjustor’s clockwise lightly tightened position. Shipping position Rebound : 10 steps back from the tightened adjustor position.

  • Page 38: Spring Front Fork

    When using an optional spring for the kit fork, you do not need to replace the preload tube. Use the original tube fitted to the fork. • A spanner ( ) and rod ( ) are supplied with the front fork SPECIAL TOOLS SPECIAL TOOLS (14B-23102-70). • Use Yamaha M1 suspension oil. – 35 –...
  • Page 39 Front Fork Spring Replacement Method 1. Turn the damping adjustor and preload adjustor anticlockwise to set to the weakest position. 2. After fixing the axle bracket in a vice, turn the fork bolt anticlockwise to lower the outer tube until the dust seal touches the upper surface of the axle bracket. Rebound damping adjustor Preload adjustor Fork bolt...
  • Page 40 5. Remove the push rod and fit the rod ( ) to the piston rod. SPECIAL TOOLS (SPECIAL TOOLS) 6. Grip the rod ( ) firmly and remove the spanner ( SPECIAL TOOLS SPECIAL TOOLS NOTICE Be very careful to apply downward pressure on the rod ( ) when you SPECIAL TOOLS remove the spanner (...
  • Page 41 8. Remove the washer, special nut and spring guide and replace the spring. NOTICE Be very careful to apply downward pressure on the rod ( ) when you SPECIAL TOOLS remove the spanner ( SPECIAL TOOLS Washer Special nut Spring guide 9.

  • Page 42: Seat Cushion (13S-24713-70)

    20. Seat Cushion (13S-24713-70) Parts List PART No. PART NAME Q’TY REMARKS 13S-24713-70 CUSHION SEAT Anti slip seat. Cut to any size for use. – 39 –...

  • Page 43: Front Spare Wheel Ass'y (4C8-25100-70)

    21. Front Spare Wheel ASS’Y (4C8-25100-70) Parts List PART No. PART NAME Q’TY REMARKS 4C8-25160-00 CAST WHEEL ASSY. MAT BLACK 93900-00030 VALVE, RIM *This kit does not include a tire. This part is an assembly of bearings, spacers and an air valve in a STD wheel. –...

  • Page 44: Rear Spare Wheel Ass'y (4C8-25300-70)

    22. Rear Spare Wheel ASS’Y (4C8-25300-70) Parts List PART No. PART NAME Q’TY REMARKS 4C8-25370-00 WHEEL,CAST MAT BLACK 93900-00030 VALVE, RIM *This kit does not include a tire. This part is an assembly of bearings, spacers and an air valve in a STD wheel. –...

  • Page 45: Throttle Set (14B-C6300-70)

    23. Throttle Set (14B-C6300-70) Parts List PART No. PART NAME Q’TY REMARKS ° 2C0-26281-70 CAP, GRIP UPPER 5FL-26282-00 CAP, GRIP UNDER ° 5SL-26243-71 TUBE, GUIDE Linear type ° 2C0-26391-70 CLIP, WIRE 1 ° 14B-26311-70 WIRE, THROTTLE 1 Grip side, Pull side Stamp:14B-70-1 Plated color:Black °...
  • Page 46 Pull side (Black) Release side (White) Pull side (Black) Release side (White) Machining off the boss. Scrap away CAP, GRIP UPPER of the kit as shown above Pull side (Black) Air filter side Release side (White) Engine side Throttle body –...

  • Page 47: Throttle Set (14B-C6300-80)

    24. Throttle Set (14B-C6300-80) Parts List PART No. PART NAME Q'TY REMARKS 2C0-26281-70 CAP, GRIP UPPER ° 5FL-26282-00 CAP, GRIP UNDER 5SL-26243-71 TUBE, GUIDE Linear type ° 2C0-26391-70 CLIP, WIRE 1 ° 14B-26301-70 THROTTLE WIRE ASSY., 1 Pull side ° Stamp:14B-80-1 Plated color:Black 14B-26302-70...
  • Page 48 Pull side (Black) Release side (White) Pull side (Black) Machining off the boss. Release side (White) Pull side (Black) Scrap away CAP, GRIP UPPER Air filtre side of the kit as shown above Release side (White) Engine side Throttle body –...

  • Page 49: Tube Guide (5Vy-26243-80)

    25. Tube Guide (5VY-26243-80) Parts List PART No. PART NAME Q'TY REMARKS 5VY-26243-80 TUBE, GUIDE Progressive type About the Throttle Tube Guide Specifications As shown below, the operating angle of the throttle grip up to when the throttle body opening is 25% is the same as STD, and the operating angle of the throttle grip when the throttle is fully opened is 58°.

  • Page 50: Installing Electrical Parts

    2-3 Installing Electrical Parts 26. ECU Set (14B-8591A-70) Parts List PART No. PART NAME Q'TY REMARKS 14B-8591A-70 13S-2818Y-80 YMS, MANUAL • Use of this set and a wire harness included in the kit enables regulation (or setting) of fuel injection and ignition timing, etc. •...

  • Page 51: Cable Interface (13S-8533A-70)

    27. Cable Interface (13S-8533A-70) Parts List PART No. PART NAME Q'TY REMARKS 13S-8533A-70 CABLE, INTERFACE 13S-N81CD-70 8cm CD USB driver • This cable connects the kit wire harness to the personal computer on which YEC FI Matching System (YMS) is installed. •...
  • Page 52 Diagnosis Functions • Use of the ECU in the kit and the harness allows functioning of the following codes in the STD diagnosis. * YMS-Monitor: YEC FI Matching System also allows functioning of the code shown below. CODE Contents *YMS-Monitor Throttle sensor TPS 1(deg) Atmospheric pressure sensor...
  • Page 53 Self-Diagnosis Functions • The ECU and harness in the kit provide the functions for the following codes of standard self-diagnosis: CODE Description All functions normally. Cam angle sensor malfunctions. Crank angle sensor malfunctions. Intake pressure sensor malfunctions (open circuit / short circuit). Intake pressure sensor malfunctions (piping system).

  • Page 54: Wire Harness Set (14B-F2590-70)

    28. Wire Harness Set (14B-F2590-70) Parts List PART No. PART NAME Q'TY REMARKS 14B-82590-70 WIRE HARNESS ASSY. 5GF-83976-00 SW., HANDLE 1 PIT ROAD LIMITER 14B-83976-70 SW., HANDLE 1 Map select 2C0-82509-70 WIRE, SUB-LEAD 4C8-82188-70 RESISTOR ASSY. Finished with joint in Wire Harness.
  • Page 55 Installing Wire Harness: 1. Remove the STD wire harness from the chassis. 2. Install the wire harness from the kit by reference to the service manual. 3. Pass the wire harness through the hole in the cable holder side and secure it with a clamp at the location indicated.
  • Page 56 NOTICE When the oil catcher tank is in use, change the direction of the hose clip so it won't touch the wire harness. Wire harness – 53 –...
  • Page 57 NOTICE The wire from the ACM is designed to be so long that for routing it, enough care should be taken not to allow it to hang out of the chassis or to interfere with other parts. To ACM To wire harness Rectifier/Regulator Wire harness –...
  • Page 58 Installing ECU: 1. Cut the shaded area off the battery box (to provide an installation area for fixing for BRKT5 seat). 58.4 43.7 2. Install BRKT5 with bolt and washer at the location where the STD mudguard was installed. 3. Install BRKT4 to BRKT5 with bolt , collar , and grommet .
  • Page 59 Installing Rectifier/Regulator: 1. Remove from the chassis the STD rectifier/regulator that is installed on the right side of the radiator. 2. Install the rectifier/regulator to the catcher tank from the kit using the STD chassis bolts. 3. In case the oil catcher tank is not used from the kit, install the rectifier/regulator using the supplied bracket , grommet , spacer , and bolt .
  • Page 60 • Map select switches Map 1 and Map 2 of the YMS “Comp. FUEL.” NOTICE When switching to Map 1 or Map 2 using “Map Select” while riding, check that proper riding is possible even when using either map. • The switches (2 types) supplied in this set enable the map select and pit road limiter to be used.
  • Page 61 • The switch installed to the STD machine may be used as is. (See diagram 3.) (Digram 3) Main switch Pit road limiter ON OFF Engine stop Not used switch Map select Lo → Map 1 Hi → Map 2 Starter Pit road limiter switch...
  • Page 62 NOTICE Do not connect the coupler for resistor (black, 2-prong) and the coupler for power (white, 2-prong). Connecting them may cause a malfunction. (See diagram 6) • This harness has a coupler that connects to the 2D made data logger. For details of the specifications of the data logger, please access the website.

  • Page 63: Headlight Harness Set (14B-F4350-70)

    29. Headlight Harness Set (14B-F4350-70) Parts List PART No. PART NAME Q’TY REMARKS 14B-84359-70 CORD, HEAD LIGHT 5JJ-81950-20 RELAY ASSY. 5GF-83976-00 SW., HANDLE 1 For emergency 5RT-83963-00 SW., HANDLE 3 On-off, kill 4C8-84312-70 CORD ASSY. This set is used in endurance races in combination with the kit harness for turning on the STD headlights and taillights.

  • Page 64: Acm Set (14B-F1400-70)

    30. ACM Set (14B-F1400-70) Parts List PART No. PART NAME Q’TY REMARKS 14B-81410-70 STATOR ASSY. 14B-81450-70 ROTOR ASSY. 14B-15411-70 COVER, CRANKCASE 1 14B-15414-70 COVER, 1 14B-1541H-70 BOND, COVER Adhesive 90149-06080 SCREW 14B-15451-70 GSKT., CRANKCASE COVER 1 This ACM is designed to have less inertial mass and friction by making it into an inner rotor type.

  • Page 65: Tightening Torque List

    Tightening Torque List Engine To be tightened Part No. Part Name Thread dia. Tightening Q’ty Remarks torque N•m pitch (kgf•m) Plug for sand 90340-18002 PLUG, M18 x 1.5 42±4 APPLY LOCK- STRAIGHT (4.3±0.4) drain hole SCREW AGENT (LOCKTITE® TO BOTH SCREW THREAD AND TAPERED...
  • Page 66 Engine To be tightened Part No. Part Name Thread dia. Tightening Q’ty Remarks torque N•m pitch (kgf•m) CON ROD 5VY-11654-01 BOLT, M8 x 0.75 TURN OF NUT APPLY “SUM- CON-ROD METHOD: BIG END RETIGHTEN TO MORI 5VY-1165A-01 SNUG TORQUE ASSEMBLY (Long bolt) OF 19.6 (2.0) •...
  • Page 67 Engine To be tightened Part No. Part Name Thread dia. Tightening Q’ty Remarks torque N•m pitch (kgf•m) Tighten DRAIN 90340-14132 PLUG M14 x 1.5 43±4 (4.3±0.4) BOLT Install PIPE, 90110-06182 BOLT, M6 x 1.0 10±2 HEXAGON (1.0±0.2) SOCKET HEAD Install 90110-06173 BOLT, M6 x 1.0...
  • Page 68 Engine To be tightened Part No. Part Name Thread dia. Tightening Q’ty Remarks torque N•m pitch (kgf•m) NUT, RING X 90179-08410 M8 x 1.25 20±2 (2.0±0.2) CYLINDER HEAD EX. PIPE 90105-08063 BOLT, M8 x 1.25 20±2 FLANGE (2.0±0.2) (DIFFUSER) X MUFFLER Install EX.
  • Page 69 Engine To be tightened Part No. Part Name Thread dia. Tightening Q’ty Remarks torque N•m pitch (kgf•m) Implant in 90116-10051 BOLT, M10 x 1.25 8 TARGETED APPLY OIL TO – STUD AT 6 9 (0.8 BOTH SCREW CRANKCASE 1 TARGETED AT THREAD AND 0.6-0.9) BEARING...
  • Page 70 Engine To be tightened Part No. Part Name Thread dia. Tightening Q’ty Remarks torque N•m pitch (kgf•m) Install COVER1 90110-06323 BOLT M6 x 1.0 12±2 CAM CHAIN (1.2±0.2) COVER Install COVER 90110-05326 BOLT M6 x 1.0 12±2 BREATHER (1.2±0.2) COVER Install PLATE, 90149-06071 SCREW...
  • Page 71 Engine To be tightened Part No. Part Name Thread dia. Tightening Q’ty Remarks torque N•m pitch (kgf•m) Install IDLER 90110-06223 BOLT, M6 x 1.0 10±2 HEXAGON (1.0±0.2) GEAR SOCKET HEAD Install 90149-06158 SCREW M6 x 1.0 14±2 (1.4±0.2) STARTER CLUTCH HOLDER Install CLUTCH 4C8-16377-00...
  • Page 72 Engine To be tightened Part No. Part Name Thread dia. Tightening Q’ty Remarks torque N•m pitch (kgf•m) – Install 90110-05063 BOLT, M5 x 0.8 – HEXAGON (0.4 0.6) NEUTRAL SOCKET SWITCH HEAD – Install COVER, 97702-50514 SCREW, M5 x 0.8 –...
  • Page 73 Chassis To be tightened Part No. Part Name Thread dia. Tightening torque Q’ty Remarks N•m (kgf•m) pitch – HANDLE, 91314-08030 BOLT, M8 x 1.25 – HEXAGON (2.3 2.8) CROWN & SOCKET OUTER TUBE HEAD – HANDLE, 90170-28419 NUT, HEX- M28 x 1.0 –...
  • Page 74 Chassis To be tightened Part No. Part Name Thread dia. Tightening torque Q’ty Remarks N•m (kgf•m) pitch ARM & FRAME 90105-10150 BOLT, M10 x 1.25 — SCREW IN FLANGE FROM THE LEFT SIDE. – 95602-10200 NUT, U M10 x 1.25 –...
  • Page 75 Chassis To be tightened Part No. Part Name Thread dia. Tightening torque Q’ty Remarks N•m (kgf•m) pitch – FRONT WHEEL 90105-14002 BOLT, M14 x 1.5 – FLANGE (7.1 11.3) SHAFT & FLANGE BOLT – REAR WHEEL 90185-24007 NUT, SELF M24 x 1.5 –...
  • Page 76 Tightening the Cylinder Head Tightening the Cylinder Head (Turn-of-Nut Method) 1. Tighten the bolts in the tightening sequence of 1 to 10 to a snug torque of 25N•m (2.5kgf•m). 2. Retighten the bolts in the tightening sequence of 1 to 2 to a turn-of-nut angle of 145°±5°. 3.
  • Page 77 Installing the Crankcase Tightening the bolts 1. Tighten the bolts in the tightening sequence of 1 to 10 to 29.4N•m (3.0kg•m). 2. After loosening the bolts once in the tightening sequence of 1 to 10, retighten them one by one to 17.6N•m (1.8kg•m). 3.
  • Page 78 – 75 –...

  • Page 79: Headlight Cord Wiring Diagram

    – 76 –...

  • Page 80: Yzf-R1 Wiring Diagram

    YZF-R1 Wiring Diagram – 77 –...
  • Page 81 Published by YAMAHA MOTOR ENGINEERING co., LTD...

This manual is also suitable for:

2009 yzf-r1

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