YZF-R1P YZF-R1PC ASSEMBLY MANUAL LIT-11666-15-47 –1– 5PW-28107-10
FOREWORD SYMBOLS USED IN ASSEMBLY MANUAL This Assembly Manual contains the information required for the correct reassembly of this Yamaha motorcycle prior to delivery to the customer. Since some external parts of the motorcycle have been removed at the Yamaha factory for the convenience of packing, assembly by the Yamaha dealer is required. It should be noted that the reassembled motorcycle should be thoroughly cleaned, inspected, and adjusted prior to delivery to the customer.
PREPARATION To assemble the motorcycle correctly, supplies and working space are required. Supplies oils, greases, shop rags. Workshop The workshop where the motorcycle is assembled should be clean and large. The floor should be level. Self-protection Protect your eyes with suitable safety spectacles or safety goggles when using compressed air, when grinding or when doing any operation which may cause particles to fly off. Product hands and feet by wearing safety gloves or doing.
UNPACKING 1. Remove the frame cover 1. NOTE: To remove the frame cover, cut the vinyl bands around the cover using a cutter or scissors. 2. Remove the bolts 2 (upper bracket). 3. Remove the bolt 3 (front tire). 4. Remove the packing frames 4 (upward and sideways). NOTE: Remove the bolts while holding frame. NOTE: Before starting the assembly, check for damaged or missing parts. The parts are contained in the cartan and the motorcycle for damage, scratches and other defects.
PARTS LOCATION 1 Carton box –2–
1 Carton box Vinyl bag 1 Plugs (handle crown) Screw, washer and special nuts (windscreen) Bolt (front master cylinder) Bolt (handle crown and handlebar) Nut (rear view mirror) Front reflector Rear view mirrors Windscreen Nut (front reflector) Owner’s manual –3–
SETUP PROCEDURES 2 54 1 3 6 –4–
1. Handlebar 1 Reservoir tank (brake) 1 2 Hexagon socket bolt 1 3 Crown nut 1 4 Hexagon socket bolt 5 6 * V d = 6 (0.24),r= 12 (0.47) 1 * d = 6 (0.24),r= 25 (0.98) Cap 2 V Hexagon socket bolt 1 * A: Tighten the crown nut to specified torque. V d = 8 (0.31),r= 30 (1.18) C: Tighten the bolt to specified torque. Tightening torque: 115 Nm (11.5 m • kg, 85.0 ft • lb) Tightening torque: 13 Nm (1.3 m • kg, 4.4 ft • lb) B: Tighten the bolt to specified torque.
4. Rear view mirror 1 Rear view mirror (left and right) 2 C 2 Cap nut 4 V 1 Windscreen 1 C 2 Special nut 6 V d = 5 (0.20) 3 Washer 6 V d = 5.5 (0.22) 4 Screw 6 V d = 5 (0.20),r= 15 (0.59) * * * * * * d = 6 (0.24) 5. Windscreen CAUTION: The windscreen is made of an acrylate resin. Take care so that it is not scratched. 6. Battery 1 Battery 1 2 Bolt 2 3 Band 1 4 Front seat 1 5 Collar 2 6 Bolt 2 A: Before installing the battery, charge the battery.
CABLE ROUTING CAUTION: Proper cable and lead routing is essential to insure safe machine operation. Clutch cable Pass the throttle cable in front of the brake hose. Pass the clutch cable behind the front fork. In this area, the handlebar switch lead (right side) should not be in front of the throttle cable. It should not cross the throttle cable around the guide-air. Î In this area, pass the handlebar switch right side lead behind of the throttle cable.
1 (–) lead 2 (+) lead –8–
ADJUSTMENTS AND PREDELIVERY SERVICE B PQL K E M A J N O I J N B F H C –9– L D I J G
A. CHECKING AND CHARGING THE BATTERY NOTE: The battery used in this motorcycles is a new version maintenance free “Valve Regulated Lead Acid Battery”, it has been pre-filled with electrolyte at the factory so there is no need for you to add any fluid at any time. 1. Check: Using a digital voltmeter, the state of a discharged MF battery can be checked by measuring opencircuit voltage (the voltage measured with the positive and negative terminals being disconnected). Open-circuit voltage Charging time 12.
EAA00129 C. CHECKING THE ENGINE OIL LEVEL 1.Stand the motorcycle on a level surface. NOTE: • Place the motorcycle on a suitable stand. • Make sure that the motorcycle is upright. NOTE: Recommended oil classification: API Service “SE”, “SF” and “SG” type or equivalent (e.g. “SF-SE”, “SFSE-CC”, “SF-SE-SD” etc.). CAUTION: 2. Let the engine idle for a few minutes. 3. Check: • engine oil level The engine oil level should be between the minimum level marks a and maximum level marks b.
EAA00140 E. ADJUSTING THE ENGINE IDLING SPEED NOTE: Prior to adjusting the engine idling speed, the throttle body synchronization should be adjusted properly, the air filter should be clean, and the engine should have adequate compression. 1. Start the engine and let it warm up for several minutes. 2. Attach: • digital tachometer (to the spark plug lead of cylinder #1) 3. Measure: • engine idling speed Out of specification → Adjust. 2. Adjust: • engine idling speed ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a.
EAA00146 H. ADJUSTING THE REAR BRAKE c. Tighten the locknut 1 to specification. T. R. 1. Measure: • brake pedal position (distance a from the top of the rider footrest to the top of the brake pedal) Out of specification → Adjust. Locknut 16 Nm (1.6 m • kg,12 ft • lb) WARNING Brake pedal position (below the bottom of the rider footrest bracket) 38 ~ 42 mm (1.50 ~ 1.65 in) 2. Adjust: • brake pedal position ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Loosen the locknut 1. b.
Å EAA00154 J. BLEEDING THE BRAKE SYSTEM HYDRAULIC WARNING Bleed the hydraulic brake system whenever: • the system was disassembled, • a brake hose was loosened or removed, • the brake fluid level is very low, • brake operation is faulty. ı NOTE: • Be careful not to spill any brake fluid or allow the brake fluid reservoir to overflow. • When bleeding the hydraulic brake system, make sure that there is always enough brake fluid before applying the brake.
EAA00159 L. ADJUSTING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. Rebound damping CAUTION: WARNING • Always adjust both front fork legs evenly. Uneven adjustment can result in poor handling and loss of stability. • Securely support the motorcycle so that there is no danger of it falling over. Never go beyond the maximum or minimum adjustment positions. 1. Adjust : • rebound damping ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a.
EAA00169 M. ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY Rebound damping WARNING Securely support the motorcycle so that there is no danger of it falling over. CAUTION: Never go beyond the maximum or minimum adjustment positions. Spring preload CAUTION: Never go beyond the maximum or minimum adjustment positions. 1. Adjust : • rebound damping ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Turn the adjusting screw 3 in direction a or b. 1.
EAA00178 N. ADJUSTING THE DRIVE CHAIN SLACK NOTE: The drive chain slack must be checked at the tightest point on the chain. CAUTION: 4. Loosen: • wheel axle nut 1 5. Adjust: • drive chain slack ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ A drive chain that is too tight will overload the engine and other vital parts, and one that is too loose can skip and damage the swingarm or cause an accident. Therefore, keep the drive chain slack within the specified limits. a. Loosen both locknuts 2. b.
EAA00185 Q. ADJUSTING THE DIGITAL CLOCK Turn the key to “ON”. To change the display to the clock mode, push the “SELECT” button 3 for at least one second. To change the display back to the prior mode, push the “SELECT” button 3. 1. Adjust: • digital clock 1 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Push the “SELECT” button 3 and “RESET” button 2 together for at least two seconds. b. When the hour digits start flashing, push the “RESET” button 2 to set the hours. c.
APPENDICES SERVICE DATA YZF-R1P/YZF-R1PC Engine idling speed: 1,000 ~ 1,100 r/min Spark plug: Type Gap CR9EIA 9 (NGK), IU27D (DENSO) 0.8 ~ 0.9 mm (0.031 ~ 0.035 in) Fuel: Recommended fuel Fuel tank capacity Valve clearance (cold): Maximum load Premium unleaded gasoline only 17 L (3.74 Imp gal, 4.49 US gal) Total: IN EX 202 kg (445 lb) for USA 201 kg (443 lb) for California * Up to 90 kg (198 lb) load Tire pressure 0.11 ~ 0.20 mm (0.0043 ~ 0.0079 in) 0.21 ~ 0.27 mm (0.0083 ~ 0.
TIGHTENING TORQUE Tightening torque Thread size Part to be tightened Engine: Spark plugs Engine oil drain bolt Chassis: Upper bracket and front fork Steering stem nut Handlebar and front fork Handlebar and upper bracket Lower ring nut Lower bracket pinch bolts Main switch and handle crown Brake fluid reservoir cap stopper Front brake hose union bolts Front brake master cylinder and bracket Meter and cowling stay Headlight and cowling stay Upper cowling and headlight Side, bottom cowling and frame, engine W
Tightening torque Thread size Part to be tightened Lean angle cut-off switch sensor and battery box Rider footrest bracket and frame Passenger footrest bracket and frame Rear master cylinder Rear brake hose union bolts Sidestand Front wheel axle and bolt Rear wheel axle nut Front brake caliper and front fork Brake disc and wheel Rear wheel sprocket and rear wheel drive hub Brake caliper and bleed screw Pinch bolt (front wheel axle) M4 M8 M8 M6 M10 M10 M14 M24 M10 M6 M10 M8 M8 Nm m • kg ft • lb 2 28 28
YAMAHA MOTOR CO., LTD. 2500 SHINGAI IWATA SHIZUOKA JAPAN PRINTED IN U.S.A.