Yamaha Yzf r1 2004 – 2006 Service Repair Manual + Parts Catalogue
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Yamaha Yzf r1 2004 – 2006 Service Repair Manual + Parts Catalogue
This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha dealers 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 dealers and will appear in future editions of this manual where applicable.
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.
1 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”.
2 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.
3 Sub-section titles appear in smaller print than the section title.
TABLE OF CONTENTS:
Yamaha Yzf r1 2004 – 2006 Service Repair Manual + Parts Catalogue
CHAPTER 1
GENERAL INFORMATION
MOTORCYCLE IDENTIFICATION 1-1
VEHICLE IDENTIFICATION NUMBER 1-1
MODEL LABEL1-1
FEATURES1-2
INSTRUMENT FUNCTIONS 1-2
IMPORTANT INFORMATION1-6
PREPARATION FOR REMOVAL AND DISASSEMBLY 1-6
REPLACEMENT PARTS 1-6
GASKETS, OIL SEALS AND O-RINGS1-6
LOCK WASHERS/PLATES AND COTTER PINS1-7
BEARINGS AND OIL SEALS1-7
CIRCLIPS 1-7
CHECKING THE CONNECTIONS 1-8
SPECIAL TOOLS 1-9
CHAPTER 2
SPECIFICATIONS
GENERAL SPECIFICATIONS 2-1
ENGINE SPECIFICATIONS 2-2
CHASSIS SPECIFICATIONS2-11
ELECTRICAL SPECIFICATIONS 2-15
CONVERSION TABLE2-18
GENERAL TIGHTENING TORQUE SPECIFICATIONS 2-18
TIGHTENING TORQUES2-19
ENGINE TIGHTENING TORQUES 2-19
CHASSIS TIGHTENING TORQUES2-23
LUBRICATION POINTS AND LUBRICANT TYPES 2-25
ENGINE2-25
CHASSIS 2-26
COOLING SYSTEM DIAGRAMS 2-27
ENGINE OIL LUBRICATION CHART 2-29
LUBRICATION DIAGRAMS 2-30
CABLE ROUTING2-35
CHAPTER 3
PERIODIC CHECKS AND ADJUSTMENTS
INTRODUCTION 3-1
PERIODIC MAINTENANCE CHART FOR THE EMISSION
CONTROL SYSTEM 3-1
GENERAL MAINTENANCE AND LUBRICATION CHART 3-1
SEATS 3-3
FUEL TANK3-4
REMOVING THE FUEL TANK 3-5
REMOVING THE FUEL PUMP 3-5
INSTALLING THE FUEL PUMP 3-6
INSTALLING THE FUEL TANK 3-6
COWLINGS3-7
FRONT COWLING AND SIDE COWLINGS 3-7
REAR COWLING 3-8
REMOVAL 3-9
INSTALLATION3-9
AIR FILTER CASE3-10
ENGINE3-11
ADJUSTING THE VALVE CLEARANCE 3-11
SYNCHRONIZING THE THROTTLE BODIES3-17
ADJUSTING THE EXHAUST GAS VOLUME 3-19
ADJUSTING THE ENGINE IDLING SPEED 3-21
ADJUSTING THE THROTTLE CABLE FREE PLAY 3-22
CHECKING THE SPARK PLUGS 3-23
MEASURING THE COMPRESSION PRESSURE3-24
CHECKING THE ENGINE OIL LEVEL 3-26
CHANGING THE ENGINE OIL 3-28
MEASURING THE ENGINE OIL PRESSURE3-29
ADJUSTING THE CLUTCH CABLE FREE PLAY 3-31
REPLACING THE AIR FILTER ELEMENT3-32
CHECKING THE FUEL AND BREATHER HOSES 3-33
CHECKING THE CRANKCASE BREATHER HOSE 3-34
CHECKING THE EXHAUST SYSTEM 3-35
ADJUSTING THE EXUP CABLES 3-36
CHECKING THE COOLANT LEVEL3-37
CHECKING THE COOLING SYSTEM 3-38
CHANGING THE COOLANT3-39
CHASSIS 3-42
ADJUSTING THE FRONT BRAKE 3-42
ADJUSTING THE REAR BRAKE 3-43
CHECKING THE BRAKE FLUID LEVEL 3-44
ADJUSTING THE REAR BRAKE LIGHT SWITCH 3-45
CHECKING THE FRONT AND REAR BRAKE PADS3-45
CHECKING THE FRONT AND REAR BRAKE HOSES 3-46
BLEEDING THE HYDRAULIC BRAKE SYSTEM 3-47
ADJUSTING THE SHIFT PEDAL 3-48
ADJUSTING THE DRIVE CHAIN SLACK 3-49
LUBRICATING THE DRIVE CHAIN3-50
CHECKING AND ADJUSTING THE STEERING HEAD 3-51
CHECKING THE FRONT FORK3-53
ADJUSTING THE FRONT FORK LEGS 3-54
ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY3-56
CHECKING THE TIRES 3-58
CHECKING THE WHEELS 3-60
CHECKING AND LUBRICATING THE CABLES 3-61
LUBRICATING THE LEVERS AND PEDALS 3-61
LUBRICATING THE SIDESTAND 3-61
LUBRICATING THE REAR SUSPENSION3-61
ELECTRICAL SYSTEM 3-62
CHECKING AND CHARGING THE BATTERY3-62
CHECKING THE FUSES3-67
REPLACING THE HEADLIGHT BULBS 3-69
ADJUSTING THE HEADLIGHT BEAMS 3-70
CHAPTER 4
CHASSIS
FRONT WHEEL AND BRAKE DISCS 4-1
REMOVING THE FRONT WHEEL 4-3
CHECKING THE FRONT WHEEL 4-3
CHECKING THE BRAKE DISCS4-5
INSTALLING THE FRONT WHEEL 4-6
ADJUSTING THE FRONT WHEEL STATIC BALANCE 4-7
REAR WHEEL AND BRAKE DISC 4-9
REAR WHEEL 4-9
REAR BRAKE DISC AND REAR WHEEL SPROCKET 4-10
REMOVING THE REAR WHEEL4-12
CHECKING THE REAR WHEEL4-13
CHECKING THE REAR WHEEL DRIVE HUB4-13
CHECKING AND REPLACING THE REAR WHEEL
SPROCKET4-13
INSTALLING THE REAR WHEEL 4-14
ADJUSTING THE REAR WHEEL STATIC BALANCE4-14
FRONT AND REAR BRAKES 4-15
FRONT BRAKE PADS4-15
REAR BRAKE PADS 4-16
REPLACING THE FRONT BRAKE PADS 4-18
REPLACING THE REAR BRAKE PADS 4-20
FRONT BRAKE MASTER CYLINDER 4-22
REAR BRAKE MASTER CYLINDER 4-25
DISASSEMBLING THE FRONT BRAKE MASTER
CYLINDER 4-27
DISASSEMBLING THE REAR BRAKE MASTER
CYLINDER 4-27
CHECKING THE FRONT AND REAR BRAKE MASTER
CYLINDERS 4-28
ASSEMBLING AND INSTALLING THE FRONT BRAKE
MASTER CYLINDER 4-29
ASSEMBLING THE REAR BRAKE MASTER CYLINDER 4-31
FRONT BRAKE CALIPERS 4-33
REAR BRAKE CALIPER 4-35
DISASSEMBLING THE FRONT BRAKE CALIPERS4-37
DISASSEMBLING THE REAR BRAKE CALIPER4-38
CHECKING THE FRONT AND REAR BRAKE CALIPERS 4-39
ASSEMBLING AND INSTALLING THE FRONT BRAKE
CALIPERS 4-40
ASSEMBLING AND INSTALLING THE REAR
BRAKE CALIPER 4-42
FRONT FORK 4-44
FRONT FORK LEGS 4-44
REMOVING THE FRONT FORK LEGS4-47
DISASSEMBLING THE FRONT FORK LEGS4-48
CHECKING THE FRONT FORK LEGS4-49
ASSEMBLING THE FRONT FORK LEGS 4-50
INSTALLING THE FRONT FORK LEGS 4-55
HANDLEBARS4-56
REMOVING THE HANDLEBARS 4-58
CHECKING THE HANDLEBARS4-58
INSTALLING THE HANDLEBARS 4-58
CHECKING THE STEERING DAMPER4-60
STEERING HEAD 4-61
UNDER BRACKET4-61
REMOVING THE UNDER BRACKET 4-63
CHECKING THE STEERING HEAD4-63
INSTALLING THE STEERING HEAD 4-64
REAR SHOCK ABSORBER ASSEMBLY 4-65
HANDLING THE REAR SHOCK ABSORBER AND
GAS CYLINDER 4-66
DISPOSING OF A REAR SHOCK ABSORBER AND
GAS CYLINDER 4-66
REMOVING THE REAR SHOCK ABSORBER ASSEMBLY4-67
CHECKING THE REAR SHOCK ABSORBER ASSEMBLY 4-68
INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY4-68
SWINGARM AND DRIVE CHAIN 4-69
REMOVING THE SWINGARM 4-71
REMOVING THE DRIVE CHAIN4-72
CHECKING THE SWINGARM 4-72
CHECKING THE DRIVE CHAIN4-73
INSTALLING THE SWINGARM 4-75
CHAPTER 5
ENGINE
ENGINE5-1
DRIVE SPROCKET 5-1
EXHAUST PIPE 5-2
LEADS AND HOSES 5-5
ENGINE5-7
INSTALLING THE ENGINE 5-9
CAMSHAFT5-11
CYLINDER HEAD COVER 5-11
CAMSHAFTS 5-13
REMOVING THE CAMSHAFTS5-14
CHECKING THE CAMSHAFTS 5-15
CHECKING THE TIMING CHAIN, CAMSHAFT SPROCKETS,
AND TIMING CHAIN GUIDES 5-17
CHECKING THE TIMING CHAIN TENSIONER 5-17
INSTALLING THE CAMSHAFTS5-19
CYLINDER HEAD 5-22
REMOVING THE CYLINDER HEAD5-23
CHECKING THE CYLINDER HEAD5-23
INSTALLING THE CYLINDER HEAD 5-24
VALVES AND VALVE SPRINGS5-25
REMOVING THE VALVES 5-27
CHECKING THE VALVES AND VALVE GUIDES 5-28
CHECKING THE VALVE SEATS5-30
CHECKING THE VALVE SPRINGS5-31
CHECKING THE VALVE LIFTERS 5-32
INSTALLING THE VALVES 5-32
STARTER CLUTCH AND GENERATOR 5-35
STATOR COIL ASSEMBLY 5-35
STARTER CLUTCH 5-37
REMOVING THE GENERATOR5-38
REMOVING THE STARTER CLUTCH 5-39
CHECKING THE DAMPER 5-39
CHECKING THE STARTER CLUTCH 5-40
INSTALLING THE STARTER CLUTCH5-41
INSTALLING THE GENERATOR5-41
CRANKSHAFT POSITION SENSOR 5-43
REMOVING THE CRANKSHAFT POSITION SENSOR 5-44
INSTALLING THE CRANKSHAFT POSITION SENSOR5-44
CLUTCH5-46
CLUTCH COVER 5-46
PULL LEVER SHAFT5-47
CLUTCH5-48
REMOVING THE CLUTCH 5-50
CHECKING THE FRICTION PLATES 5-52
CHECKING THE CLUTCH PLATES5-52
CHECKING THE CLUTCH SPRINGS 5-53
CHECKING THE CLUTCH HOUSING 5-53
CHECKING THE CLUTCH BOSS 5-53
CHECKING THE PRESSURE PLATE 5-54
CHECKING THE PULL LEVER SHAFT AND PULL ROD 5-54
INSTALLING THE CLUTCH 5-54
SHIFT SHAFT 5-58
SHIFT SHAFT AND STOPPER LEVER5-58
REMOVING THE SHIFT SHAFT5-60
CHECKING THE SHIFT SHAFT5-61
CHECKING THE STOPPER LEVER 5-61
INSTALLING THE SHIFT SHAFT 5-61
OIL PAN AND OIL PUMP5-63
REMOVING THE OIL PAN 5-66
CHECKING THE SPROCKET AND CHAIN5-66
CHECKING THE OIL PUMP 5-67
CHECKING THE RELIEF VALVE 5-67
CHECKING THE OIL DELIVERY PIPE AND OIL PIPE 5-68
CHECKING THE OIL STRAINER 5-68
CHECKING THE OIL NOZZLES5-68
ASSEMBLING THE OIL PUMP 5-68
INSTALLING THE OIL/WATER PUMP ASSEMBLY 5-69
INSTALLING THE OIL PAN 5-71
CRANKCASE 5-72
DISASSEMBLING THE CRANKCASE 5-74
CHECKING THE CRANKCASE 5-75
CHECKING THE BEARINGS AND OIL SEALS 5-75
ASSEMBLING THE CRANKCASE 5-75
CONNECTING RODS AND PISTONS 5-77
REMOVING THE CONNECTING RODS AND PISTONS5-78
REMOVING THE CRANKSHAFT ASSEMBLY5-79
CHECKING THE CYLINDER AND PISTON 5-79
CHECKING THE PISTON RINGS 5-80
CHECKING THE PISTON PINS5-81
CHECKING THE BIG END BEARINGS5-82
INSTALLING THE CONNECTING ROD AND PISTON 5-86
CRANKSHAFT5-92
CHECKING THE CRANKSHAFT5-93
CHECKING THE CRANKSHAFT DRIVE SPROCKET 5-93
CHECKING THE CRANKSHAFT JOURNAL BEARINGS5-93
INSTALLING THE CRANKSHAFT 5-96
TRANSMISSION 5-97
TRANSMISSION, SHIFT DRUM ASSEMBLY AND
SHIFT FORKS 5-97
REMOVING THE TRANSMISSION 5-103
CHECKING THE SHIFT FORKS5-103
CHECKING THE SHIFT DRUM ASSEMBLY 5-104
CHECKING THE TRANSMISSION 5-104
INSTALLING THE TRANSMISSION5-105
CHAPTER 6
COOLING SYSTEM
RADIATOR 6-1
CHECKING THE RADIATOR6-3
INSTALLING THE RADIATOR 6-4
OIL COOLER 6-5
CHECKING THE OIL COOLER 6-7
INSTALLING THE OIL COOLER6-7
THERMOSTAT6-8
CHECKING THE THERMOSTAT6-10
ASSEMBLING THE THERMOSTAT ASSEMBLY 6-11
INSTALLING THE THERMOSTAT ASSEMBLY 6-11
WATER PUMP 6-12
IMPELLER SHAFT6-12
DISASSEMBLING THE WATER PUMP6-14
CHECKING THE WATER PUMP6-14
ASSEMBLING THE WATER PUMP6-15
CHAPTER 7
FUEL INJECTION SYSTEM
FUEL INJECTION SYSTEM 7-1
WIRING DIAGRAM 7-2
ECU’S SELF-DIAGNOSTIC FUNCTION 7-4
SUBSTITUTE CHARACTERISTICS OPERATION CONTROL
(FAIL-SAFE ACTION)7-5
FAIL-SAFE ACTIONS TABLE 7-5
TROUBLESHOOTING CHART 7-7
DIAGNOSTIC MODE 7-8
TROUBLESHOOTING DETAILS7-15
THROTTLE BODIES 7-35
INJECTORS7-37
CHECKING THE INJECTORS 7-39
CHECKING THE THROTTLE BODIES7-39
CHECKING THE THROTTLE BODY JOINTS 7-39
CHECKING THE PRESSURE REGULATOR 7-40
CHECKING THE FUEL PUMP AND PRESSURE REGULATOR
OPERATION 7-40
CHECKING AND ADJUSTING THE THROTTLE POSITION
SENSOR 7-41
CHECKING AND ADJUSTING THE SUB-THROTTLE POSITION
SENSOR 7-43
CHECKING AND ADJUSTING THE THERMO WAX 7-45
AIR INDUCTION SYSTEM 7-46
AIR INJECTION 7-46
AIR CUT-OFF VALVE7-46
AIR INDUCTION SYSTEM DIAGRAMS7-47
CHECKING THE AIR INDUCTION SYSTEM 7-48
CHAPTER 8
ELECTRICAL SYSTEM
ELECTRICAL COMPONENTS 8-1
CHECKING SWITCH CONTINUITY8-3
CHECKING THE SWITCHES8-4
CHECKING THE BULBS AND BULB SOCKETS8-5
TYPES OF BULBS8-5
CHECKING THE CONDITION OF THE BULBS 8-5
CHECKING THE CONDITION OF THE BULB SOCKETS 8-6
CHECKING THE LEDs 8-7
IGNITION SYSTEM 8-8
CIRCUIT DIAGRAM 8-8
TROUBLESHOOTING8-10
ELECTRIC STARTING SYSTEM8-14
CIRCUIT DIAGRAM 8-14
STARTING CIRCUIT CUT-OFF SYSTEM OPERATION 8-15
TROUBLESHOOTING8-16
STARTER MOTOR8-19
CHECKING THE STARTER MOTOR 8-21
ASSEMBLING THE STARTER MOTOR 8-22
CHARGING SYSTEM8-24
CIRCUIT DIAGRAM 8-24
TROUBLESHOOTING8-25
LIGHTING SYSTEM 8-27
CIRCUIT DIAGRAM 8-27
TROUBLESHOOTING8-29
CHECKING THE LIGHTING SYSTEM 8-31
SIGNALING SYSTEM8-34
CIRCUIT DIAGRAM 8-34
TROUBLESHOOTING8-36
CHECKING THE SIGNALING SYSTEM 8-36
COOLING SYSTEM 8-43
CIRCUIT DIAGRAM 8-43
TROUBLESHOOTING8-45
FUEL PUMP SYSTEM8-48
CIRCUIT DIAGRAM 8-48
FUEL PUMP SYSTEM8-49
TROUBLESHOOTING8-50
CHECKING THE FUEL PUMP 8-52
SELF-DIAGNOSIS8-53
TROUBLESHOOTING8-54
CHAPTER 9
TROUBLESHOOTING
STARTING FAILURES 9-1
ENGINE 9-1
FUEL SYSTEM 9-1
ELECTRICAL SYSTEMS 9-1
INCORRECT ENGINE IDLING SPEED 9-2
ENGINE 9-2
FUEL SYSTEM 9-2
ELECTRICAL SYSTEMS 9-2
POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE 9-2
ENGINE 9-2
FUEL SYSTEM 9-2
FAULTY GEAR SHIFTING9-3
SHIFTING IS DIFFICULT 9-3
SHIFT PEDAL DOES NOT MOVE 9-3
JUMPS OUT OF GEAR9-3
FAULTY CLUTCH 9-3
CLUTCH SLIPS9-3
CLUTCH DRAGS 9-3
OVERHEATING 9-4
ENGINE 9-4
COOLING SYSTEM9-4
FUEL SYSTEM 9-4
CHASSIS9-4
ELECTRICAL SYSTEMS 9-4
OVERCOOLING9-4
COOLING SYSTEM9-4
POOR BRAKING PERFORMANCE 9-4
FAULTY FRONT FORK LEGS9-5
LEAKING OIL 9-5
MALFUNCTION9-5
UNSTABLE HANDLING 9-5
FAULTY LIGHTING OR SIGNALING SYSTEM9-6
HEADLIGHT DOES NOT COME ON9-6
HEADLIGHT BULB BURNT OUT9-6
TAIL/BRAKE LIGHT DOES NOT COME ON 9-6
TAIL/BRAKE LIGHT BULB BURNT OUT 9-6
TURN SIGNAL DOES NOT COME ON 9-6
TURN SIGNAL BLINKS SLOWLY9-6
TURN SIGNAL REMAINS LIT9-6
TURN SIGNAL BLINKS QUICKLY 9-6
HORN DOES NOT SOUND 9-6
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