Yamaha YZF-R1 2000 User Manual [ru]

4 (1)

FOREWORD

This Supplementary Service Manual has been prepared to introduce new service and data for the YZF-R1 2000. For complete service information procedures it is necessary to use this Supplementary Service Manual together with the following manual.

YZF-R1 SERVICE MANUAL: 4XV1-AE1

YZF-R1 2000

SUPPLEMENTARY

SERVICE MANUAL1999 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.

EB001000

NOTICE

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.

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.

NOTE:

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!

WARNING

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

 

 

the motorcycle operator, a bystander or

 

 

 

 

a person checking or repairing the mo-

 

 

torcycle.

 

 

 

 

 

CAUTION:

 

A CAUTION indicates special precautions that must be taken to avoid damage

NOTE:

to the motorcycle.

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 ªSYMBOLSº.

2Each chapter is divided into sections. The current section title is shown at the top of each page, except in Chapter 3 (ªPERIODIC CHECKS AND ADJUSTMENTSº), where the sub-section title(-s) appears.

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 ªSYMBOLSº.

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 sequentially.

6 2 1

3

4

5

8

7

1

2

GEN

SPEC

INFO

 

3

4

CHK

ENG

ADJ

 

5

6

COOL

CARB

7

8

CHAS

ELEC

9

10

TRBL

 

SHTG

 

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

EB004000

SYMBOLS

The following symbols are not relevant to every vehicle.

Symbols 1 to 9 indicate 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.

10Serviceable with engine mounted

11Filling fluid

12Lubricant

13Special tool

14Tightening torque

15Wear limit, clearance

16Engine speed

17Electrical data

Symbols 18 to 23 in the exploded diagrams indicate the types of lubricants and lubrication points.

18Engine oil

19Gear oil

20Molybdenum disulfide oil

21Wheel bearing grease

22Lithium soap base grease

23Molybdenum disulfide grease

Symbols 24 to 25 in the exploded diagrams indicate the following.

24Apply locking agent (LOCTITE )

25Replace 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)

GENERAL SPECIFICATIONS

 

SPEC

 

SPECIFICATIONS

 

 

 

 

 

 

 

 

GENERAL SPECIFICATIONS

 

 

 

 

 

 

 

 

 

 

Item

Standard

 

 

Limit

 

 

 

 

 

 

Dimensions

 

 

 

 

 

Overall length

2,035 mm

 

 

 

 

2,095 mm (for AUS)

 

 

 

Overall width

695 mm

 

 

 

Overall height

1,105 mm

 

 

 

Seat height

815 mm

 

 

 

Wheelbase

1,395 mm

 

 

 

Minimum ground clearance

140 mm

 

 

 

Minimum turning radius

3,400 mm

 

 

 

 

 

 

 

 

 

Weight

 

 

 

 

 

Wet (with oil and a full fuel tank)

194 kg

 

 

 

Dry (without oil and fuel)

175 kg

 

 

 

Maximum load (total of cargo, rider,

201 kg

 

 

 

passenger, and accessories)

 

 

 

 

 

 

 

 

 

 

 

±1±

 

ENGINE SPECIFICATIONS

 

SPEC

 

ENGINE SPECIFICATIONS

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Item

Standard

 

 

Limit

 

 

 

 

 

 

Engine

 

 

 

 

 

Engine type

Liquid-cooled, 4-stroke, DOHC

 

 

 

 

Displacement

998 cm3

 

 

 

 

Cylinder arrangement

Forward-inclined parallel 4-cylinder

 

 

 

 

Bore stroke

74 58 mm

 

 

 

 

Compression ratio

11.8 : 1

 

 

 

 

Engine idling speed

1,000 1,100 r/min

 

 

 

 

Vacuum pressure at engine idling

29.3 kPa (220 mm Hg)

 

 

 

 

speed

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

 

 

Standard compression pressure

 

 

(at sea level)

 

 

 

 

 

 

 

 

 

 

 

Fuel

 

 

 

 

 

Recommended fuel

Regular unleaded gasoline

 

 

 

 

 

Unleaded fuel (for AUS)

 

 

 

 

Fuel tank capacity

 

 

 

 

 

Total (including reserve)

18 L

 

 

 

 

Reserve only

3.8 L

 

 

 

 

 

 

 

 

 

 

Engine oil

 

 

 

 

 

Lubrication system

Wet sump

 

 

 

 

Recommended oil

 

 

 

 

 

Temp.

 

 

 

 

 

 

SAE20W40SE or SAE10W30SE

 

 

 

 

Quantity

 

 

Total amount

3.6 L

 

Without oil filter cartridge

2.7 L

 

replacement

 

 

With oil filter cartridge replacement

2.9 L

 

Oil pressure (hot)

45 kPa at 1,100 r/min

 

 

(0.45 kgf/cm2 at 1,100 r/min)

 

Relief valve opening pressure

490 570 kPa (4.9 5.7 kgf/cm2)

 

±2±

 

ENGINE SPECIFICATIONS

 

SPEC

 

 

 

 

 

 

 

 

 

 

Item

Standard

 

Limit

 

 

 

 

 

Camshafts

 

 

 

 

Drive system

Chain drive (right)

 

 

Camshaft cap inside diameter

24.500 X 24.521 mm

 

 

Camshaft journal diameter

24.459 X 24.472 mm

 

 

Camshaft-journal-to-camshaft-

0.028 X 0.062 mm

 

 

cap clearance

 

 

 

 

Intake camshaft lobe dimensions

 

 

 

 

Measurement A

32.5 X 32.6 mm

32.4 mm

Measurement B

24.95 X 25.05 mm

24.85 mm

Measurement C

7.45 X 7.65 mm

 

Exhaust camshaft lobe dimensions

Measurement A

32.95 X 33.05 mm

32.85 mm

Measurement B

24.95 X 25.05 mm

24.85 mm

Measurement C

7.75 X 7.95 mm

 

Max. camshaft runout

 

0.03 mm

±3±

 

ENGINE SPECIFICATIONS

 

SPEC

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Item

 

Standard

 

 

Limit

 

 

 

 

 

 

 

Valves, valve seats, valve guides

 

 

 

 

 

 

Valve clearance (cold)

 

 

 

 

 

 

Intake

 

0.11 X 0.20 mm

 

 

 

Exhaust

 

0.21 X 0.25 mm

 

 

 

Valve dimensions

 

 

 

 

 

 

 

 

 

 

 

 

 

Head Diameter

Face Width

Seat Width

Margin Thickness

Valve head diameter A

 

 

 

Intake

 

22.9 X 23.1 mm

 

Exhaust

 

24.4 X 24.6 mm

 

Valve face width B

 

 

 

Intake

 

1.76 X 2.90 mm

 

Exhaust

 

1.76 X 2.90 mm

 

Valve seat width C

 

 

 

Intake

 

0.9 X 1.1 mm

 

Exhaust

 

0.9 X 1.1 mm

 

Valve margin thickness D

 

 

 

Intake

 

0.5 X 0.9 mm

 

Exhaust

 

0.5 X 0.9 mm

 

Valve stem diameter

 

 

 

Intake

 

3.975 X 3.990 mm

3.945 mm

Exhaust

 

4.465 X 4.480 mm

4.43 mm

Valve guide inside diameter

 

 

 

Intake

 

4.000 X 4.012 mm

4.05 mm

Exhaust

 

4.500 X 4.512 mm

4.55 mm

Valve-stem-to-valve-guide clearance

 

 

Intake

 

0.010 X 0.037 mm

0.08 mm

Exhaust

 

0.020 X 0.047 mm

0.1 mm

Valve stem runout

 

 

0.01 mm

Valve seat width

 

 

Intake

0.9 X 1.1 mm

 

Exhaust

0.9 X 1.1 mm

 

 

 

 

Connecting rods

 

 

Crankshaft-pin-to-big-end-bearing

0.031 X 0.055 mm

 

clearance

 

 

Bearing color code

±1 = Violet 0 = White 1 = Blue 2 = Black

 

±4±

 

ENGINE SPECIFICATIONS

 

SPEC

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Item

 

Standard

 

 

Limit

 

 

 

 

 

 

 

Transmission

 

 

 

 

 

 

Transmission type

 

Constant mesh, 6-speed

 

 

 

Primary reduction system

 

Spur gear

 

 

 

Primary reduction ratio

 

68/43 (1.581)

 

 

 

Secondary reduction system

 

Chain drive

 

 

 

Secondary reduction ratio

 

43/16 (2.688)

 

 

 

Operation

 

Left-foot operation

 

 

 

Gear ratios

 

 

 

 

 

 

1st gear

 

35/14 (2.500)

 

 

 

2nd gear

 

35/19 (1.842)

 

 

 

3rd gear

 

30/20 (1.500)

 

 

 

4nd gear

 

28/21 (1.333)

 

 

 

5th gear

 

30/25 (1.200)

 

 

 

6th gear

 

29/26 (1.115)

 

 

 

Max. main axle runout

 

 

 

 

0.08 mm

Max. drive axle runout

 

 

 

 

0.08 mm

 

 

 

 

 

 

 

Carburetors

 

 

 

 

 

 

Model (manufacturer) quantity

 

BDSR40 (MIKUNI) 4

 

 

 

Throttle cable free play (at the

 

3 5 mm

 

 

 

flange of the throttle grip)

 

 

 

 

 

 

ID mark

 

5JJ1 00

 

 

 

Main jet

 

#130

 

 

 

Main air jet

 

Carburetors 1 and 4: #60

 

 

 

 

 

Carburetors 2 and 3: #65

 

 

 

 

Jet needle

 

6DEY5-53-3

 

 

 

Needle jet

 

P-OM

 

 

 

Pilot air jet

 

#120

 

 

 

Pilot outlet

 

1.0

 

 

 

Pilot jet

 

#15

 

 

 

Bypass 1

 

0.8

 

 

 

Bypass 2

 

0.9

 

 

 

Bypass 3

 

0.8

 

 

 

Pilot screw turns out

 

3.125

 

 

 

Valve seat size

 

1.5

 

 

 

±5±

 

CHASSIS SPECIFICATIONS

 

SPEC

 

CHASSIS SPECIFICATIONS

 

 

 

 

 

 

 

 

 

 

Item

Standard

 

Limit

 

 

 

 

 

Front tire

 

 

 

 

Tire type

Tubeless

 

 

Size

120/70 ZR17 (58W)

 

 

Model (manufacturer)

MEZ3Y FRONT (METZELER)

 

 

 

D207FQ (DUNLOP)

 

 

 

Tire pressure (cold)

250 kPa (2.5 kg/cm2, 2.5 bar)

 

 

 

0 90 kg

 

 

90 197 kg

250 kPa (2.5 kg/cm2, 2.5 bar)

 

 

High-speed riding

250 kPa (2.5 kg/cm2, 2.5 bar)

 

 

Min. tire tread depth

 

 

1.6 mm

 

 

 

 

 

Rear tire

 

 

 

 

Tire type

Tubeless

 

 

Size

190/50 ZR17 (73W)

 

 

Model (manufacturer)

MEZ3Y (METZELER)/D207N (DUNLOP)

Tire pressure (cold)

250 kPa (2.5 kg/cm2, 2.5 bar)

 

 

 

0 90 kg

 

 

90 197 kg

290 kPa (2.9 kg/cm2, 2.9 bar)

 

 

High-speed riding

250 kPa (2.5 kg/cm2, 2.5 bar)

 

 

Min. tire tread depth

 

 

1.6 mm

 

 

 

 

 

Rear brake

 

 

 

 

Brake type

Single-disc brake

 

 

Operation

Right-foot operation

 

 

Brake pedal position (from the top

35 40 mm

 

 

of the brake pedal to the bottom of

 

 

 

 

the rider footrest bracket)

 

 

 

 

Recommended fluid

DOT 4

 

 

Brake discs

 

 

 

 

Diameter thickness

245 5 mm

 

 

Min. thickness

 

 

4.5 mm

Max. deflection

 

 

0.1 mm

Brake pad lining thickness

5.5 mm

 

0.5 mm

Master cylinder inside diameter

12.7 mm

 

Caliper cylinder inside diameter

38.2 mm

 

±6±

 

CHASSIS SPECIFICATIONS

 

SPEC

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Item

 

Standard

 

 

Limit

 

 

 

 

 

 

 

Front suspension

 

 

 

 

 

 

Suspension type

 

Telescopic fork

 

 

 

Front fork type

 

Coil spring/oil damper

 

 

 

Front fork travel

 

135 mm

 

 

 

Spring

 

 

 

 

 

 

Free length

 

255 mm

 

 

 

Spacer length

 

85 mm

 

 

 

Installed length

 

242.4 mm

 

 

 

Spring rate (K1)

 

7.35 N/mm (0.75 kgf/mm)

 

 

 

 

Spring stroke (K1)

 

0 X 135 mm

 

 

 

Optional spring available

 

No

 

 

 

Fork oil

 

 

 

 

 

 

Recommended oil

 

Suspension oil ª01º or equivalent

 

 

 

Quantity (each front fork leg)

 

482 cm3

 

 

 

Level (from the top of the inner

 

74 mm

 

 

 

tube, with the inner tube fully

 

 

 

 

 

 

compressed, and without the

 

 

 

 

 

 

fork spring)

 

 

 

 

 

 

Damper adjusting rod locknut

 

11 mm

 

 

 

distance

 

 

 

 

 

 

Spring preload adjusting positions

 

 

 

 

 

 

Minimum

 

8

 

 

 

Standard

 

6

 

 

 

Maximum

 

1

 

 

 

Rebound damping adjusting

 

 

 

 

 

 

positions

 

 

 

 

 

 

Minimum*

 

11

 

 

 

Standard*

 

5

 

 

 

Maximum*

 

1

 

 

 

Compression damping adjusting

 

 

 

 

 

 

positions

 

 

 

 

 

 

Minimum*

 

9

 

 

 

Standard*

 

5

 

 

 

Maximum*

 

1

 

 

 

*with the adjusting screw fully turned

 

 

 

 

 

in position

 

 

 

 

 

 

 

 

 

 

 

 

 

±7±

 

CHASSIS SPECIFICATIONS

 

SPEC

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Item

 

Standard

 

 

Limit

 

 

 

 

 

 

 

Rear suspension

 

 

 

 

 

 

Suspension type

 

Swingarm (link suspension)

 

 

 

Rear shock absorber assembly

 

Coil spring/gas-oil damper

 

 

 

type

 

 

 

 

 

 

Rear shock absorber assembly

 

65 mm

 

 

 

travel

 

 

 

 

 

 

Spring

 

 

 

 

 

 

Free length

 

176 mm

 

 

 

Installed length

 

162.5 mm

 

 

 

Spring rate (K1)

 

78.4 N/mm (7.84 kgf/mm)

 

 

 

Spring stroke (K1)

 

0 X 65 mm

 

 

 

Optional spring available

 

No

 

 

 

Standard spring preload gas/air

 

1,200 kPa (12 kgf/cm2)

 

 

 

pressure

 

 

 

 

 

 

Spring preload adjusting positions

 

 

 

 

 

 

Minimum

 

1

 

 

 

Standard

 

4

 

 

 

Maximum

 

9

 

 

 

Rebound damping adjusting

 

 

 

 

 

 

positions

 

 

 

 

 

 

Minimum*

 

11

 

 

 

Standard*

 

7

 

 

 

Maximum*

 

1

 

 

 

Compression damping adjusting

 

 

 

 

 

 

positions

 

 

 

 

 

 

Minimum*

 

11

 

 

 

Standard*

 

9

 

 

 

Maximum*

 

1

 

 

 

*with the adjusting screw fully turned

 

 

 

 

 

in position

 

 

 

 

 

 

 

 

 

 

 

 

 

±8±

ELECTRICAL SPECIFICATIONS

 

SPEC

 

 

 

 

 

 

 

 

ELECTRICAL SPECIFICATIONS

 

 

 

 

 

 

 

Item

Standard

 

Limit

 

 

 

 

System voltage

12 V

 

 

 

 

 

 

 

 

 

Ignition system

 

 

 

 

 

 

Ignition system type

Transistorized coil ignition

 

 

Ignition timing

5_ BTDC at 1,050 r/min

 

 

Advanced timing

55_ BTDC at 5,000 r/min

 

 

Advancer type

Throttle position sensor and electrical

 

 

Pickup coil resistance/color

248 372 W/Gy-B

 

 

Transistorized coil ignition unit

TNDF54 (DENSO)

 

 

model (manufacturer)

 

 

 

 

 

 

 

 

 

 

 

 

 

Voltage regulator

 

 

 

 

 

 

Regulator type

Semiconductor short circuit

 

 

Model

SH650A-12

 

 

No-load regulated voltage

14.1 14.9 V

 

 

 

 

 

 

 

 

 

Bulbs (voltage/wattage quantity)

 

 

 

 

 

 

Headlight

12 V 60 W/55 W 2

 

 

Auxiliary light

12 V 5 W 2

 

 

Tail/brake light

12 V 5 W/21 W 2

 

 

Turn signal light

12 V 21 W 4

 

 

Meter light

LED

 

 

 

 

 

 

 

 

 

Electric starting system

 

 

 

 

 

 

System type

Constant mesh

 

 

Starter motor

 

 

 

 

 

 

Model (manufacturer)

5JJ (YAMAHA)

 

 

Power output

0.75 kW

 

 

Brushes

 

 

 

 

 

 

Overall length

9.8 mm

 

3.65 mm

Spring force

4.88 7.32 N (488 732 gf)

 

 

Commutator resistance

0.009 0.011 Ω

 

 

Commutator diameter

24.5 mm

 

23.5 mm

Mica undercut

1.5 mm

 

 

 

 

 

 

 

 

 

Turn signal relay

 

 

 

 

 

 

Relay type

Full-transistor

 

 

Model (manufacturer)

FE246BH (DENSO)

 

 

Self-cancelling device built-in

No

 

 

Turn signal blinking frequency

75 95 cycles/min.

 

 

Wattage

21 W 2

 

 

 

 

 

 

Oil level switch model

4XV (DENSO)

 

 

(manufacturer)

 

 

 

 

 

 

 

 

 

 

Fuel pump relay model

G8R-30Y-M (OMRON)

 

 

(manufacturer)

 

 

 

 

 

 

±9±

 

ELECTRICAL SPECIFICATIONS

 

SPEC

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Item

 

Standard

 

 

Limit

 

 

 

 

 

 

 

Thermo unit

 

 

 

 

 

 

Model (manufacturer)

 

5JJ (NIPPON THERMOSTAT)

 

 

 

 

 

 

 

 

 

Fuses (amperage quantity)

 

 

 

 

 

Main fuse

 

30 A 1

 

 

 

Headlight fuse

 

20 A 1

 

 

 

Signaling system fuse

 

20 A 1

 

 

 

Ignition fuse

 

15 A 1

 

 

 

Radiator fan fuse

 

10 A 1

 

 

 

Backup fuse (odometer)

 

10 A 1

 

 

 

Reserve fuse

 

30 A 1

 

 

 

 

 

20 A 1

 

 

 

 

 

15 A 1

 

 

 

 

 

10 A 1

 

 

 

 

 

 

 

 

 

 

±10±

 

TIGHTENING TORQUES

 

 

SPEC

 

TIGHTENING TORQUES

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

ENGINE TIGHTENING TORQUES

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Thread

 

 

Tightening

 

 

Item

Fastener

Q'ty

 

torque

Remarks

size

 

 

 

 

 

Nm

m kgf

 

 

 

 

 

 

 

 

 

Cylinder head

Nut

M10

8

50

5.0

 

 

 

Cylinder head

Cap nut

M10

2

65

6.5

 

 

 

Generator rotor

Bolt

M10

1

65

6.5

 

 

 

Oil/water pump assembly driven

Bolt

M6

1

12

1.2

 

 

 

sprocket cover

 

 

 

 

 

 

 

 

 

 

 

Air induction system hose

Clamp

M7

4

4

0.4

 

 

 

Crankcase

Bolt

M9

10

 

See NOTE

 

 

 

Crankcase

Bolt

M6

2

 

 

 

 

 

 

14

1.4

 

 

Crankcase

Bolt

M6

14

12

1.2

 

 

 

Crankcase

Bolt

M8

2

24

2.4

 

 

 

Ignitor unit

Screw

M5

2

7

0.7

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

NOTE:

After tightening to 15 Nm (1.5 m kg), tighten another 45_ X 50_

±11±

 

TIGHTENING TORQUES

 

 

SPEC

 

CHASSIS TIGHTENING TORQUES

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Item

 

Thread size

Tightening

Remarks

 

 

 

 

 

 

Nm

m kgf

 

 

 

 

 

Lower ring nut

 

M30

9

0.9

See NOTE.

Engine mounting

 

 

 

 

 

 

 

 

Front mounting bolts

 

M10

40

4.0

 

 

Rear upper mounting bolt

 

M10

55

5.5

 

 

Rear under mounting bolts

 

M10

55

5.5

 

 

Pinch bolts

 

M8

24

2.4

 

 

Exhaust pipe bracket

 

M8

24

2.4

 

 

Rear master cylinder

 

M8

18

1.8

 

 

 

 

 

 

 

 

 

 

 

NOTE:

1.First, tighten the ring nut to approximately 18 Nm (1.8 m kg) with a torque wrench, then loosen the ring nut completely.

2.Retighten the ring nut to specification.

±12±

LUBRICATION POINTS AND LUBRICANT TYPES SPEC

E202000

LUBRICATION POINTS AND LUBRICANT TYPES

ENGINE LUBRICATION POINTS AND LUBRICANT TYPES

Lubrication point

Lubricant

Connecting rod bolts and nuts

±13±

OIL FLOW DIAGRAMS SPEC

EB203000

OIL FLOW DIAGRAMS

1Intake camshaft

2Exhaust camshaft

3Crankshaft

4Oil cooler

5Oil pipe

6Oil strainer

7Oil pump

±14±

OIL FLOW DIAGRAMS SPEC

1Exhaust camshaft

2Intake camshaft

3Oil filter

±15±

Yamaha YZF-R1 2000 User Manual

OIL FLOW DIAGRAMS SPEC

1Cylinder head

2Crankshaft

±16±

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