Shipping position: 15 steps back from the tightened adjustor position. Page 40 — 36 — Page Spring Rear Shock You can also use two shims together. Page Front Fork Assy Page 44 Damping Adjustment Method Turn clockwise to increase the damping force and anticlockwise to reduce the damping force.
Shipping position Rebound : 10 steps back from the tightened adjustor position. Page 45 — 41 — Page 46 — 42 — Page Spring Front Fork FORK Turn the damping adjustor and preload adjustor anticlockwise to set to the weakest position.
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 49 5. Remove the push rod and fit the rod to the piston rod. Page 50 8. Remove the washer, special nut and spring guide and replace the spring. Page 51 References Front and rear load changes and front and rear suspension movement in different scenarios. Load change The wider the throttle is opened, the more the load is concentrated on the rear. Front fork Reaches nearly maximum extended stroke. Page Seat Cushion 13S Cut to any size for use.
This part is an assembly of bearings, spacers and an air valve in a STD wheel. Page Throttle Set 14B-C Page Tube Guide 5Vy Page Cable Interface 13SA Cam angle sensor malfunctions. Crank angle sensor malfunctions.
Intake pressure sensor malfunctions piping system. Finished with joint in Wire Harness. Page 65 Installing Wire Harness: 1. Remove the STD wire harness from the chassis. Install the wire harness from the kit by reference to the service manual. Pass the wire harness through the hole in the cable holder side and secure it with a clamp at the location indicated. Wire harness — 62 — Page 67 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.
Page 68 Installing ECU: 1. Cut the shaded area off the battery box to provide an installation area for fixing for BRKT5 seat.
Page 71 x The switch installed to the STD machine may be used as is. See diagram 3. Connecting them may cause a malfunction. See diagram 6. Synchronize carburetor 4 to carbure- tor 3 by turning the synchronizing screw 2 in either direction until both gauges read the same. Carburetor side a. Loosen the locknut 2 on the deceler- ator cable. Turn the adjusting nut 3 in direction a or b to take up any slack on the decelerator cable.
Check that the mark a is within the required firing range b on the pickup coil rotor. NOTE: The ignition timing is not adjustable. Compression pressure at sea level Minimum 1, kPa Lubricate the O-ring 3 of the new oil filter cartridge with a thin coat of engine oil. Slightly loosen the oil gallery bolt 1. Start the engine and keep it idling until engine oil starts to seep from the oil gallery bolt. If no engine oil comes out after one minute, turn the engine off so that it will not seize.
Disconnect the EXUP servomotor coupler 1. Loosen both locknuts 1. Start the engine, warm it up for several minutes, and then turn it off. If water is used instead of coolant, check, and if necessary, correct the antifreeze concentration of the cool- ant.
However, soft water may be used if distilled water is not available. While pushing the brake lever for- ward, turn the adjusting dial 1 until the brake lever is in the desired posi- tion. Loosen the locknut 1. Turn the adjusting bolt 2 in direction a or b until the specified brake pedal position is obtained. Direction a Brake pedal is raised. Direction b Brake pedal is lowered.
Stand the motorcycle on a level surface. Operate the brake. Fill the brake fluid reservoir to the proper level with the recommended brake fluid.
Install the brake fluid reservoir dia- phragm. Connect a clear plastic hose 1 tightly to the bleed screw 2. Installed shift rod length mm 2. Rotate the rear wheel several times and check the drive chain to locate its tight- est point. If the drive chain is not main- tained properly, it will wear out rapidly.
Therefore, the drive chain should be ser- viced, especially when the motorcycle is used in dusty areas. Loosen the lower ring nut completely, then tighten it to specification. Lower ring nut final tighten- ing torque 9 Nm 0. Uneven adjustment can result in poor handling and loss of stability. Turn the adjusting screw 1 in direc- tion a or b. Rebound damping is Direction a increased suspension is harder. Page The front and rear tires should always be by the same manufacturer and of the same design.
No guarantee concerning handling characteristics can be given if a tire combination other than one approved by Yamaha is used on this motorcycle. Front tire Manufacturer Size Therefore, the charge of the battery has to be checked by measuring the voltage at the battery terminals. Install a new fuse of the correct amperage.
Direction a Headlight beam is raised. Headlight beam is low- Direction b ered. Page Chapter 4. Locknut Shift rod Drive sprocket cover Lock washer Drive sprocket Shift arm For installation, reverse the removal procedure. Coolant Drain. Ground lead Disconnect. Starter motor Stator coil assembly coupler Disconnect.
Pickup coil coupler Disconnect. Oil level switch connector Disconnect. Neutral switch Speed sensor For connecting, reverse the disconnec- tion procedure. NOTE: Place a suitable stand under the frame and engine. Pinch bolt Loosen. Right front mounting bolt Washer Spacer Left front mounting bolt Washer Self-locking nut Rear mounting bolt Spacer For installation, reverse the removal Spark plug Cylinder head cover Cylinder head cover gasket When piston 1 is at TDC on the com- pression stroke, align mark a on the pickup coil rotor with the crankcase mating surface b.
Camshaft lobe dimensions limit Intake camshaft a Lightly press the timing chain ten- sioner rod into the timing chain ten- sioner housing by hand. While pressing the timing chain ten- sioner rod, wind it clockwise with a thin screwdriver 1 until it stops. Cylinder head Cylinder head gasket Dowel pin For installation, reverse the removal procedure.
After all of the bolts and nuts are fully loosened, remove them. NOTE: To ensure an even surface, rotate the cylinder head several times. Intake valve lifter Intake valve pad Intake valve cotter Intake valve upper spring seat Intake valve spring Intake valve oil seal NOTE: Before removing the internal parts of the cylinder head e.
Valve spring compressor Attachment for the intake valve for the exhaust valve 4. Remove the valve guide with a valve guide remover 1. Valve margin thickness 0. Install the valve into the cylinder head. Press the valve through the valve guide and onto the valve seat to make a clear impression. Apply a fine lapping compound to the valve face and repeat the above steps. After every lapping procedure, be sure to clean off all of the lapping compound from the valve face and valve seat.
Engine oil Drain. Rotor holding tool 4. Pickup coil Pickup coil rotor For installation, reverse the removal procedure. After all of the bolts are fully loosened, remove them. Page Rotor holding tool 3. Clutch cable Clutch cover Clutch cover gasket Circlip Pull lever Pull lever spring Pull lever shaft Oil seal Bearing For installation, reverse the removal procedure. Straighten the lock washer tab. NOTE: Pitting on the clutch boss splines will cause erratic clutch operation. Install the starter clutch gear 1 onto the starter clutch 2 and hold the starter clutch.
Clutch holding tool 4. Bend the lock washer tab along a flat side of the nut. Make sure that the pull rod teeth and pull lever shaft pinion gear are engaged. Throttle stop screw holder Shift shaft cover Shift shaft cover gasket Dowel pin Shift shaft Shift shaft spring Oil baffle plate Oil baffle plate Oil delivery pipe Bearing After all of the bolts are fully loos- ened, remove them. Thoroughly wash the crankcase halves in a mild solvent. Thoroughly clean all the gasket surfaces and crankcase mating surfaces.
Calculate the piston-to-cylinder clear- ance with the following formula. If out of specification, replace the crankcases, and the pistons and pis- ton rings as a set. Put a piece of Plastigauge 1 on the crankshaft pin. Assemble the connecting rod halves. Free yamaha motorcycle service manuals for download. Instant download factory service repair manuals for yamaha tradebit offers hundreds of motorcycle service repair manuals for your yamaha yzf-r1 manuals..
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