Yamaha YZF-R1V Manual

YZF-R1V

5VY-28197-11

SUPPLEMENTARY

SERVICE MANUAL

LIT-11616-19-75

YZF-R1VC

YZF-R1LEV

YZF-R1LEVC

YZF-R1V/YZF-R1VC

YZF-R1LEV/YZF-R1LEVC

SUPPLEMENTARY

SERVICE MANUAL

Corporation, U.S.A.

First edition, October 2005

or unauthorized use without the written

permission of Yamaha Motor Corporation,

U.S.A. is expressly prohibited.

Printed in U.S.A.

LIT-11616-19-75

EAS00001

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)

EAS00030

NOTICE

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

ers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one

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

vehicles should have a basic understanding of mechanics and the techniques to repair these types

of vehicles. Repair and maintenance work attempted by anyone without this knowledge is likely to

render the vehicle unsafe and unfit for use.

This model has been designed and manufactured to perform within certain specifications in regard

to performance and emissions. Proper service with the correct tools is necessary to ensure that the

vehicle will operate as designed. 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.

Yamaha Motor Company, Ltd. is continually striving to improve all of its models. Modifications and

significant changes in specifications or procedures will be forwarded to all authorized Yamaha deal-

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

TE:

• This Service Manual contains information regarding periodic maintenance to the emission control

system. Please read this material carefully.

• Designs and specifications are subject to change without notice.

EAS00040

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!

Failure to follow WARNING instructions could result in severe injury or death

to the vehicle operator, a bystander or a person checking or repairing the

vehicle.

A CAUTION indicates special precautions that must be taken to avoid dam-

age to the vehicle.

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

WARNING

CAUTION:

NOTE:

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. An abbreviation and symbol in the upper right corner of

each page indicate the current chapter.

Refer to “SYMBOLS”.

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.

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

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

each removal and disassembly section.

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

disassembly step.

Symbols indicate parts to be lubricated or replaced.

Refer to “SYMBOLS”.

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

parts, notes in jobs, etc.

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

sequentially.

EAS00008

SYMBOLS

The following symbols are not relevant to every

vehicle.

Symbols to indicate the subject of each

chapter.

General information

Specifications

Periodic checks and adjustments

Chassis

Engine

Cooling system

Fuel injection system

Electrical system

Troubleshooting

Symbols to indicate the following.

Serviceable with engine mounted

Filling fluid

Lubricant

Special tool

Tightening torque

Wear limit, clearance

Engine speed

Electrical data

Symbols to in the exploded diagrams

indicate the types of lubricants and lubrication

points.

Engine oil

Gear oil

Molybdenum-disulfide oil

Wheel-bearing grease

Lithium-soap-based grease

Molybdenum-disulfide grease

Symbols to in the exploded diagrams

indicate the following.

Apply locking agent (LOCTITE®)

Replace the part with a new one.

CONTENTS

GENERAL INFORMATION

SPECIAL TOOLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

SPECIFICATIONS

GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

ENGINE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

CHASSIS SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

ELECTRICAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

ENGINE TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . . . . . . 7

CHASSIS TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . . . . . 8

LUBRICATION POINTS AND LUBRICANT TYPES . . . . . . . . . . . . . . 9

ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

LUBRICATION DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

CABLE ROUTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

PERIODIC CHECKS AND ADJUSTMENTS

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

PERIODIC MAINTENANCE CHART FOR THE EMISSION

CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

GENERAL MAINTENANCE AND LUBRICATION CHART . . . . . . . . 27

CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

ADJUSTING THE FRONT FORK LEGS. . . . . . . . . . . . . . . . . . . . . 29

ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY . . . . . 32

CHASSIS

FRONT WHEEL AND BRAKE DISCS . . . . . . . . . . . . . . . . . . . . . . . . . 35

REAR WHEEL AND BRAKE DISCS . . . . . . . . . . . . . . . . . . . . . . . . . . 36

REAR BRAKE DISC AND REAR WHEEL SPROCKET . . . . . . . . . 36

FRONT FORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

FRONT FORK LEGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

DISASSEMBLING THE FRONT FORK LEGS . . . . . . . . . . . . . . . . 40

CHECKING THE FRONT FORK LEGS . . . . . . . . . . . . . . . . . . . . . 42

ASSEMBLING THE FRONT FORK LEGS . . . . . . . . . . . . . . . . . . . 43

REAR SHOCK ABSORBER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 47

REMOVING THE REAR SHOCK ABSORBER ASSEMBLY . . . . . 49

INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY . . . . . 50

SWINGARM AND DRIVE CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

REMOVING THE SWINGARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

CHECKING THE SWINGARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

CHECKING THE CONNECTING ROD ASSEMBLY . . . . . . . . . . . 53

CHECKING THE DRIVE CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

ENGINE

ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

INSTALLING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

CAMSHAFTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

CLUTCH COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

REMOVING THE CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

CHECKING THE FRICTION PLATES . . . . . . . . . . . . . . . . . . . . . . 67

CHECKING THE CLUTCH PLATES. . . . . . . . . . . . . . . . . . . . . . . . 68

CHECKING THE CLUTCH SPRINGS . . . . . . . . . . . . . . . . . . . . . . 69

CHECKING THE CLUTCH HOUSING . . . . . . . . . . . . . . . . . . . . . . 69

CHECKING THE PRESSUR PLATE 2 . . . . . . . . . . . . . . . . . . . . . . 70

CHECKING THE CLUTCH BOSS . . . . . . . . . . . . . . . . . . . . . . . . . 70

CHECKING THE PRESSURE PLATE 1 . . . . . . . . . . . . . . . . . . . . . 70

CHECKING THE PULL LEVER SHAFT AND PULL ROD . . . . . . . 71

INSTALLING THE CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

YZF-R1V/YZF-R1VC/YZF-R1LEV /YZF-R1LEVC 2006 WIRING DIAGRAM

GEN

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.

When placing an order, refer to the list provided below to avoid any mistakes.

TE:

• For U.S.A. and Canada, use part number starting with “YM-”, “YU-”, or “ACC-”.

• For others, use part number starting with “90890-”.

(YZF-R1LE)

Tool No. Tool name/Function Illustration

90890-01472

Front fork cap bolt wrench

This tool is used to loosen or tighten the front

fork cap bolt.

90890-01504

Damper rod holder

This tool is used to loosening or tightening

the damper rod assembly.

Rod puller

90890-01437

YM-A8703

Rod puller

attachment

90890-01435

YM-A8703

Rod puller

Rod puller attachment

These tools are used to pull up the front fork

damper rod.

SPECIAL TOOLS

SPEC

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) •••

Weight

Wet (with oil and a full fuel tank) 194 kg (428 lb) (USA) (YZF-R1) •••

195 kg (430 lb) (CAL) (YZF-R1) •••

195 kg (430 lb) (USA) (YZF-R1LE) •••

195 kg (430 lb) (CAL) (YZF-R1LE) •••

Maximum load (except vehicle) 201 kg (443 lb) (USA) (YZF-R1) •••

200 kg (441 lb) (CAL) (YZF-R1) •••

200 kg (441 lb) (USA) (YZF-R1LE) •••

200 kg (441 lb) (CAL) (YZF-R1LE) •••

GENERAL SPECIFICATIONS

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