Yamaha YZF-R1 2000 Manual

FOREWORD

This Supplementary Service Manual has been prepared to introduce new service and data for the

YZF-R12000.ForcompleteserviceinformationproceduresitisnecessarytousethisSupplementary

Service Manual together with the following manual.

YZF-R1 SERVICE MANUAL: 4XV1-AE1

YZF-R1 2000

SUPPLEMENTARY

SERVICE MANUAL

1999 by Yamaha Motor Co., Ltd.

First Edition, December 1999

Any reproduction or unauthorized use

without the written permission of

Yamaha Motor Co., Ltd. is expressly

prohibited.

NOTE:

WARNING

CAUTION:

EB001000 NOTICE

This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha dealers

andtheirqualifiedmechanics.itisnotpossibletoincludealltheknowledgeofamechanicinonemanu-

al. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles

shouldhaveabasicunderstandingofmechanicsandthetechniquestorepair these types of vehicles.

Repair and maintenance work attempted by anyone without this knowledge is likely to render the ve-

hicle unsafe and unfit for use.

YamahaMotorCompany, Ltd.iscontinuallystrivingtoimproveallof its models. Modifications and sig-

nificant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers

and will appear in future editions of this manual where applicable.

Designs and specifications are subject to change without notice.

EB002000

IMPORTANT MANUAL INFORMATION

Particularly important information is distinguished in this manual by the following.

The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR

SAFETY IS INVOLVED!

FailuretofollowWARNINGinstructionscouldresultin severeinjuryordeathto

themotorcycleoperator, a bystanderorapersoncheckingorrepairingthe mo-

torcycle.

ACAUTIONindicatesspecialprecautionsthatmustbetakentoavoiddamage

to the motorcycle.

NOTE: A NOTE provides key information to make procedures easier or clearer.

EB003000 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.

1The manual is divided into chapters. An abbreviation and symbol in the upper right corner of each

page indicate the current chapter.

Refer to “SYMBOLS”.

2Each chapter is divided into sections. The current section title is shown at the top of each page,

exceptinChapter3(“PERIODICCHECKSANDADJUSTMENTS”),wherethesub-sectiontitle(-s)ap-

pears.

3Sub-section titles appear in smaller print than the section title.

4To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each

removal and disassembly section.

5Numbers are given in the order of the jobs in the exploded diagram. A circled number indicates a

disassembly step.

6Symbols indicate parts to be lubricated or replaced.

Refer to “SYMBOLS”.

7A job instruction chart accompanies the exploded diagram, providing the order of jobs, names of

parts, notes in jobs, etc.

8Jobs requiring more information (such as special tools and technical data) are described sequen-

tially.

24 25

2321

19 2018

16 1715

1413

11 12

GEN

INFO SPEC

ENG

CARB

ELECCHAS

COOL

CHK

ADJ

TRBL

SHTG

EB004000

SYMBOLS

The following symbols are not relevant to every

vehicle.

Symbols 1to 9indicate the subject of each

chapter.

1General information

2Specifications

3Periodic checks and adjustments

4Engine

5Cooling system

6Carburetor(-s)

7Chassis

8Electrical system

9Troubleshooting

Symbols 10 to 17 indicate the following.

10 Serviceable with engine mounted

11 Filling fluid

12 Lubricant

13 Special tool

14 Tightening torque

15 Wear limit, clearance

16 Engine speed

17 Electrical data

Symbols 18 to 23 intheexplodeddiagramsindi-

cate the types of lubricants and lubrication

points.

18 Engine oil

19 Gear oil

20 Molybdenum disulfide oil

21 Wheel bearing grease

22 Lithium soap base grease

23 Molybdenum disulfide grease

Symbols 24 to 25 intheexplodeddiagramsindi-

cate the following.

24 Apply locking agent (LOCTITE)

25 Replace the part

CONTENTS

SPECIFICATIONS

GENERAL SPECIFICATIONS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ENGINE SPECIFICATIONS 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHASSIS SPECIFICATIONS 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ELECTRICAL SPECIFICATIONS 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TIGHTENING TORQUES 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ENGINE TIGHTENING TORQUES 11. . . . . . . . . . . . . . . . . . . . . . . . .

CHASSIS TIGHTENING TORQUES 12. . . . . . . . . . . . . . . . . . . . . . .

LUBRICATION POINTS AND LUBRICANT TYPES 13. . . . . . . . . . . . .

ENGINE LUBRICATION POINTS AND LUBRICANT TYPES 13. .

OIL FLOW DIAGRAMS 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

COOLANT FLOW DIAGRAMS 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CABLE ROUTING 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PERIODIC CHECKS AND ADJUSTMENTS

INTRODUCTION 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PERIODIC MAINTENANCE AND LUBRICATION INTERVALS 33. . .

COWLINGS 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AIR FILTER CASE AND IGNITION COIL PLATE 36. . . . . . . . . . . . . . .

OVERHAULING THE ENGINE

AIR INDUCTION SYSTEM 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ENGINE 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

INSTALLING THE ENGINE 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CYLINDER HEAD 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CRANKCASE 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ASSEMBLING THE CRANKCASE 43. . . . . . . . . . . . . . . . . . . . . . . . .

COOLING SYSTEM

RADIATOR 45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CARBURETORS

AIR INDUCTION SYSTEM 47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AIR INJECTION 47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AIR CUTOFF VALVE 47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AIR INDUCTION SYSTEM DIAGRAMS 48. . . . . . . . . . . . . . . . . . . . .

CHECKING THE AIR INDUCTION SYSTEM 49. . . . . . . . . . . . . . . .

CHASSIS

FRONT WHEEL AND BRAKE DISCS 50. . . . . . . . . . . . . . . . . . . . . . . . .

INSTALLING THE FRONT WHEEL 51. . . . . . . . . . . . . . . . . . . . . . . .

FRONT AND REAR BRAKES 52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

REAR BRAKE MASTER CYLINDER AND BRAKE

FLUID RESERVOIR 52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ELECTRICAL

INSTRUMENT FUNCTIONS 53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

INDICATOR LIGHTS 53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

COOLANT TEMPERATURE WARNING LIGHT 54. . . . . . . . . . . . . .

SPEEDOMETER UNIT 55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ELECTRIC STARTING SYSTEM 57. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

STARTER MOTOR 57. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

COOLING SYSTEM 62. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CIRCUIT DIAGRAM 62. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TROUBLESHOOTING 63. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SELF-DIAGNOSIS 66. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TROUBLESHOOTING 67. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

YZF-R1 WIRING DIAGRAM (For EUR)

YZF-R1 WIRING DIAGRAM (For OCE)

–1–

GENERAL SPECIFICATIONS SPEC

SPECIFICATIONS

GENERAL SPECIFICATIONS

Item Standard Limit

Dimensions

Overall length

Overall width

Overall height

Seat height

Wheelbase

Minimum ground clearance

Minimum turning radius

2,035 mm

2,095 mm (for AUS)

695 mm

1,105 mm

815 mm

1,395 mm

140 mm

3,400 mm



Weight

Wet (with oil and a full fuel tank)

Dry (without oil and fuel)

Maximum load (total of cargo, rider,

passenger, and accessories)

194 kg

175 kg

201 kg



–2–

ENGINE SPECIFICATIONS SPEC

Temp.

ENGINE SPECIFICATIONS

Item Standard Limit

Engine

Engine type

Displacement

Cylinder arrangement

Bore stroke

Compression ratio

Engine idling speed

Vacuum pressure at engine idling

speed

Standard compression pressure

(at sea level)

Liquid-cooled, 4-stroke, DOHC

998 cm3

Forward-inclined parallel 4-cylinder

74 58 mm

11.8 : 1

1,000 1,100 r/min

29.3 kPa (220 mm Hg)

1,450 kPa (14.5 kgf/cm2) at 400 r/min



Fuel

Recommended fuel

Fuel tank capacity

Total (including reserve)

Reserve only

Regular unleaded gasoline

Unleaded fuel (for AUS)

18 L

3.8 L



Engine oil

Lubrication system

Recommended oil

Quantity

Total amount

Without oil filter cartridge

replacement

With oil filter cartridge replacement

Oil pressure (hot)

Relief valve opening pressure

Wet sump

SAE20W40SE or SAE10W30SE

3.6 L

2.7 L

2.9 L

45 kPa at 1,100 r/min

(0.45 kgf/cm2at 1,100 r/min)

490 570 kPa (4.9 5.7 kgf/cm2)



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