Yamaha YZF-R1 2006 User Manual [ru]
YZFR1W
YZFR1WC
SERVICE MANUAL
LIT-11616-20-53
4C8-28197-10
EAS20040
YZFR1W/YZFR1WC
SERVICE MANUAL
©2006 by Yamaha Motor
Corporation, U.S.A.
First edition, October 2006
All rights reserved. Any reproduction
or unauthorized use without the written
permission of Yamaha Motor Corporation,
U.S.A. is expressly prohibited.
Printed in U.S.A.
P/N LIT-11616-20-53
EAS20070
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.
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.
NOTE:
• 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.
EAS20080
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
WARNING
CAUTION:
NOTE:
the vehicle operator, a bystander or a person checking or repairing the vehicle.
A CAUTION indicates special precautions that must be taken to avoid damage
to the vehicle.
A NOTE provides key information to make procedures easier or clearer.
to
EAS20090
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 and each chapter is divided into sections. The current section
title is shown at the top of each page “1”.
• Sub-section titles appear in smaller print than the section title “2”.
• To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each
removal and disassembly section “3”.
• Numbers are given in the order of the jobs in the exploded diagram. A number indicates a disassembly step “4”.
• Symbols indicate parts to be lubricated or replaced “5”.
Refer to “SYMBOLS”.
• A job instruction chart accompanies the exploded diagram, providing the order of jobs, names of
parts, notes in jobs, etc “6”.
• Jobs requiring more information (such as special tools and technical data) are described sequentially “7”.
EAS20100
SYMBOLS
The following symbols are used in this manual
for easier understanding.
NOTE:
The following symbols are not relevant to every
vehicle.
123
456
T
.
R
.
78
16.Replace the part
91011
E
G
12 13 14
B
LS
15 16
LT
1. Serviceable with engine mounted
2. Filling fluid
3. Lubricant
4. Special tool
5. Tightening torque
6. Wear limit, clearance
7. Engine speed
8. Electrical data
9. Engine oil
10.Gear oil
11.Molybdenum-disulfide oil
12.Wheel-bearing grease
13.Lithium-soap-based grease
14.Molybdenum-disulfide grease
15.Apply locking agent (LOCTITE®)
New
M
M
EAS20110
TABLE OF CONTENTS
GENERAL INFORMATION
SPECIFICATIONS
PERIODIC CHECKS AND ADJUSTMENTS
CHASSIS
ENGINE
1
2
3
4
5
COOLING SYSTEM
FUEL SYSTEM
ELECTRICAL SYSTEM
TROUBLESHOOTING
6
7
8
9
GENERAL INFORMATION
IDENTIFICATION ..........................................................................................1-1
VEHICLE IDENTIFICATION NUMBER...................................................1-1
MODEL LABEL.......................................................................................1-1
FEATURES ...................................................................................................1-2
FI SYSTEM.............................................................................................1-3
IMPORTANT INFORMATION .....................................................................1-12
PREPARATION FOR REMOVAL AND DISASSEMBLY........................1-12
REPLACEMENT PARTS.......................................................................1-12
GASKETS, OIL SEALS AND O-RINGS................................................1-12
LOCK WASHERS/PLATES AND COTTER PINS .................................1-12
BEARINGS AND OIL SEALS ............................................................... 1-13
CIRCLIPS .............................................................................................1-13
CHECKING THE CONNECTIONS .............................................................1-14
SPECIAL TOOLS........................................................................................1-15
1
EAS20130
IDENTIFICATION
EAS20140
VEHICLE IDENTIFICATION NUMBER
The vehicle identification number “1” is
stamped into the right side of the steering
head pipe.
EAS20150
MODEL LABEL
The model label “1” is affixed to the frame. This
information will be needed to order spare
parts.
IDENTIFICATION
1-1
FEATURES
EAS20170
FEATURES
OUTLINE OF THE FI SYSTEM
The main function of a fuel supply system is to provide fuel to the combustion chamber at the optimum air-fuel ratio in accordance with the engine operating conditions and the atmospheric temperature. In the conventional carburetor system, the air-fuel ratio of the mixture that is supplied to the
combustion chamber is created by the volume of the intake air and the fuel that is metered by the jet
used in the respective carburetor.
Despite the same volume of intake air, the fuel volume requirement varies by the engine operating
conditions, such as acceleration, deceleration, or operating under a heavy load. Carburetors that
meter the fuel through the use of jets have been provided with various auxiliary devices, so that an
optimum air-fuel ratio can be achieved to accommodate the constant changes in the operating conditions of the engine.
As the requirements for the engine to deliver more performance and cleaner exhaust gases
increase, it becomes necessary to control the air-fuel ratio in a more precise and finely tuned manner. To accommodate this need, this model has adopted an electronically controlled fuel injection
(FI) system, in place of the conventional carburetor system. This system can achieve an optimum
air-fuel ratio required by the engine at all times by using a microprocessor that regulates the fuel
injection volume according to the engine operating conditions detected by various sensors.
The adoption of the FI system has resulted in a highly precise fuel supply, improved engine
response, better fuel economy, and reduced exhaust emissions.
1. Intake air temperature sensor
2. Engine trouble warning light
3. Air induction system solenoid
4. Atmospheric pressure sensor
5. Throttle position sensor (for throttle cable
pulley)
6. Throttle servo motor
7. Throttle position sensor (for throttle valves)
8. Intake funnel servo motor
9. Injector
10.Intake air pressure sensor
11.Fuel pump
12.Lean angle sensor
13.ECU (engine control unit)
1-2
14.Starting circuit cut-off relay
15.Speed sensor
16.EXUP servo motor
17.O
sensor
2
18.Crankshaft position sensor
19.Coolant temperature sensor
20.Spark plug
21.Ignition coil
22.Cylinder identification sensor
FEATURES
EAS4C81010
FI SYSTEM
The fuel pump delivers fuel to the fuel injector via the fuel filter. The pressure regulator maintains the
fuel pressure that is applied to the fuel injector at only 324 kPa (3.24 kg/cm
when the energizing signal from the ECU energizes the fuel injector, the fuel passage opens, causing the fuel to be injected into the intake manifold only during the time the passage remain open.
Therefore, the longer the length of time the fuel injector is energized (injection duration), the greater
the volume of fuel that is supplied. Conversely, the shorter the length of time the fuel injector is energized (injection duration), the lesser the volume of fuel that is supplied.
The injection duration and the injection timing are controlled by the ECU. Signals that are input from
the throttle position sensor (for throttle valves), throttle position sensor (for throttle cable pulley),
crankshaft position sensor, intake air pressure sensor, intake air temperature sensor, coolant temperature sensor, atmospheric pressure sensor, cylinder identification sensor, lean angle sensor, speed
sensor and O
sensor enable the ECU to determine the injection duration. The injection timing is
2
determined through the signals from the crankshaft position sensor. As a result, the volume of fuel
that is required by the engine can be supplied at all times in accordance with the driving conditions.
2
, 46.1 psi). Accordingly,
1. Fuel pump
2. Injector
3. Cylinder identification sensor
4. ECU (engine control unit)
5. Throttle position sensor (for throttle valves)
6. Throttle position sensor (for throttle cable
pulley)
7. Speed sensor
8. Intake air temperature sensor
9. Lean angle sensor
10.O
sensor
2
11.Catalytic converter
12.Coolant temperature sensor
13.Crankshaft position sensor
14.Intake air pressure sensor
15.Throttle servo motor
16.Throttle body
17.Atmospheric pressure sensor
18.Air filter case
19.Intake funnel servo motor
A. Fuel system
B. Air system
C. Control system
1-3
FEATURES
EAS4C81011
YCC-T (Yamaha Chip Controlled Throttle) YCC-I (Yamaha Chip Controlled Intake)
Mechanism characteristics
Yamaha developed the YCC-T and YCC-I system employing the most advanced electronic control
technologies. Electronic control throttle systems have been used on automobiles, but Yamaha has
developed a faster, more compact system specifically for the needs of a sports motorcycle. The
Yamaha-developed system has a high-speed calculating capacity that produces computations of
running conditions every 1/1000th of a second.
The YCC-T system is designed to respond to the throttle action of the rider by having the ECU
instantaneously calculate the ideal throttle valve opening and generate signals to operate the motordriven throttle valves and thus actively control the intake air volume.
The ECU contains three CPUs with a capacity about five times that of conventional units, making it
possible for the system to respond extremely quickly to the slightest adjustments made by the rider.
In particular, optimized control of the throttle valve opening provides the optimum volume of intake
air for easy-to-use torque, even in a high-revving engine.
The YCC-I system calculates the value from the engine revolution number and throttle opening rate,
activates the intake air funnel with the electronic control motor drive to control the intake pipe length
in order to gain the high power output in all revolution ranges from low speeds to high speeds.
Aims and advantages of using YCC-T system
• Increased engine power
By shortening the air intake path, higher engine speed is possible → Increased engine power.
• Improved driveability
Air intake volume is controlled according to the operating conditions → Improved throttle response
to meet engine requirement.
Driving force is controlled at the optimal level according to the transmission gear position and
engine speed → Improved throttle control.
• Engine braking control
Due to the throttle control, optimal engine braking is made possible.
• Simplified idle speed control (ISC) mechanism
The bypass mechanism and ISC actuator are eliminated → A simple mechanism is used to maintain a steady idle speed.
• Reduced weight
Compared to using a sub-throttle mechanism, weight is reduced.
1. Throttle position sensor (for throttle cable
pulley)
2. Throttle servo motor
3. Throttle position sensor (for throttle valves)
4. Throttle valves
5. Throttle cable pulley with linkage guard
A. To throttle grip
1-4
FEATURES
Aims and advantages of using YCC-I system
• Improvement of the engine power characteristics
The high power design in all ranges is now provided by having both two features of the short
intake function to ensure the power at the high speed revolution of engine, and the long intake
function to ensure the power in the practical use range.
• Intake pipe length switching control using the motor
The intake pipe length switching operation in a minute time is now available by means of the motor
drive using the electronic control.The smooth power characteristic is provided, which does not let
an operator feel the switching action by the optimization of its switching revolution number and the
most suitable application of engine at the time of changing the revolution.
A. Down position (long intake)
(Low rpm to Mid rpm)
B. Up position (short intake)
(High rpm)
1-5
YCC-T/YCC-I system outline
FEATURES
1. Throttle position sensor (for throttle cable
pulley)
2. Throttle servo motor
3. Throttle position sensor (for throttle valves)
4. ECU (engine control unit)
5. ETV main CPU (32 bit)
6. ETV sub CPU (16 bit)
7. FI CPU (32 bit)
8. Throttle servo motor driver
9. Throttle servo motor driver operation sensing/shut off circuit
10.Throttle servo motor driver operation sensing
feedback/emergency stop
11.Emergency stop
12.Engine revolution (pulse signal)
13.Sensor input
14.Neutral switch
15.Crankshaft position sensor
16.Speed sensor
17.Coolant temperature sensor
18.Atmospheric pressure sensor
19.Intake funnel servo motor driver
20.Intake funnel servo motor
1-6
YCC-T/YCC-I control outline
FEATURES
1. Throttle position sensor (for throttle cable
pulley)
2. Throttle position sensor (for throttle valves)
3. Crankshaft position sensor
4. Speed sensor
5. Coolant temperature sensor
6. Neutral switch
7. Atmospheric pressure sensor
8. Accelerator position (two signals)
9. Throttle position (two signals)
10.Engine revolution
11.Vehicle speed
12.Coolant temperature
13.Neutral/In gear
14.Atmospheric pressure
15.Throttle servo motor
16.ECU (engine control unit)
17.Base map
18.Idle speed control
19.Calculated throttle valve opening angle
20.Base map
21.Air funnel position (Calculation value)
22.Intake funnel servo motor
1-7
FEATURES
EAS4C81024
INSTRUMENT FUNCTIONS
Multi-function meter unit
1. Clock
2. Speedometer
3. “SELECT” button
4. “RESET” button
5. Tachometer
6. Coolant temperature display/air intake temperature display
7. Odometer/tripmeters/fuel reserve tripmeter/ stopwatch
8. Shift timing indicator light
EWA4C81008
WARNING
Be sure to stop the vehicle before making
any setting changes to the multi-function
meter unit.
The multi-function meter unit is equipped with
the following:
• a speedometer (which shows the riding
speed)
• a tachometer (which shows engine speed)
• an odometer (which shows the total distance
traveled)
• two tripmeters (which show the distance traveled since they were last set to zero)
• a fuel reserve tripmeter (which shows the
distance traveled since the fuel level warning
light came on)
•a clock
• a coolant temperature display
• an air intake temperature display
• a self-diagnosis device
• a display brightness and shift timing indicator
light control mode
NOTE:
• Be sure to turn the key to “ON” before using
the “SELECT” and “RESET” buttons.
• To switch the speedometer and odometer/
tripmeter displays between kilometers and
miles, press the “SELECT” button for at least
one second.
Tachometer
1. Tachometer
2. Tachometer red zone
The electric tachometer allows the rider to
monitor the engine speed and keep it within
the ideal power range.
When the key is turned to “ON”, the tachometer needle will sweep once across the r/min
range and then return to zero r/min in order to
test the electrical circuit.
ECA4C81017
CAUTION:
Do not operate the engine in the tachometer red zone.
Red zone: 13750 r/min and above
Clock mode
1. Clock
Turn the key to “ON”.
To set the clock
1. Push the “SELECT” button and “RESET”
button together for at least two seconds.
2. When the hour digits start flashing, push
the “RESET” button to set the hours.
3. Push the “SELECT” button, and the minute
digits will start flashing.
1-8
FEATURES
4. Push the “RESET” button to set the minutes.
5. Push the “SELECT” button and then
release it to start the clock.
Odometer, tripmeter, and stopwatch modes
1. Odometer/tripmeter/fuel reserve tripmeter
Push the “SELECT” button to switch the display between the odometer mode “ODO” and
the tripmeter modes “TRIP A” and “TRIP B”
and the stopwatch mode in the following order:
TRIP A → TRIP B → ODO → Stopwatch →
TRIP A
If the fuel level warning light comes on, the
odometer display will automatically change to
the fuel reserve tripmeter mode “F-TRIP” and
start counting the distance traveled from that
point. In that case, push the “SELECT” button
to switch the display between the various tripmeter, odometer, and stopwatch modes in the
following order:
F-TRIP → Stopwatch → TRIP A → TRIP B →
ODO → F-TRIP
To reset a tripmeter, select it by pushing the
“SELECT” button, and then push the “RESET”
button for at least one second. If you do not
reset the fuel reserve tripmeter manually, it will
reset itself automatically and the display will
return to the prior mode after refueling and
traveling 5 km (3 mi).
Stopwatch mode
To change the display to the stopwatch mode,
select it by pushing the “SELECT” button. (The
stopwatch digits will start flashing.) Release
the “SELECT” button, and then push it again
for a few seconds until the stopwatch digits
stop flashing.
Standard measurement
1. Push the “RESET” button to start the stopwatch.
2. Push the “SELECT” button to stop the stopwatch.
3. Push the “SELECT” button again to reset
the stopwatch.
Split-time measurement
1. Push the “RESET” button to start the stopwatch.
2. Push the “RESET” button or start switch
“ ” to measure split-times. (The colon “:”
will start flashing.)
3. Push the “RESET” button or start switch
“ ” to measure split-times. (The colon “:”
will start flashing.)
4. Push the “SELECT” button to reset the
stopwatch.
NOTE:
To change the display back to the prior mode,
push the “SELECT” button for a few seconds.
Coolant temperature display
1. Coolant temperature display
The coolant temperature display indicates the
temperature of the coolant.
Push the “RESET” button to switch the coolant
temperature display to the air intake temperature display.
NOTE:
When the coolant temperature display is
selected, “C” is displayed for one second, and
then the coolant temperature is displayed.
ECA4C81018
CAUTION:
Do not operate the engine if it is overheated.
1-9
FEATURES
Air intake temperature display
1. Air intake temperature display
The air intake temperature display indicates
the temperature of the air drawn into the air filter case. Push the “RESET” button to switch
the coolant temperature display to the air
intake temperature display.
NOTE:
• Even if the air intake temperature is set to be
displayed, the coolant temperature warning
light comes on when the engine overheats.
• When the key is turned to “ON”, the coolant
temperature is automatically displayed, even
if the air intake temperature was displayed
prior to turning the key to “OFF”.
• When the air intake temperature display is
selected, “A” is displayed before the temperature.
Self-diagnosis device
1. Error code display
This model is equipped with a self-diagnosis
device for various electrical circuits.
If any of those circuits are defective, the engine
trouble warning light will come on, and then the
display will indicate a two-digit error code.
Display brightness and shift timing indicator light control mode
1. Display brightness
2. Shift timing indicator light activation/deactivation
3. Shift timing indicator light
4. Brightness level
This mode cycles through five control functions, allowing you to make the following settings in the order listed below.
Display brightness:
• This function allows you to adjust the brightness of the displays and tachometer to suit
the outside lighting conditions.
• Shift timing indicator light activity:
This function allows you to choose whether
or not the indicator light should be activated
and whether it should flash or stay on when
activated.
• Shift timing indicator light activation:
This function allows you to select the engine
speed at which the indicator light will be activated.
• Shift timing indicator light deactivation:
This function allows you to select the engine
speed at which the indicator light will be
deactivated.
• Shift timing indicator light brightness:
This function allows you to adjust the brightness of the indicator light to suit your preference.
NOTE:
In this mode, the right display shows the current setting for each function (except the shift
timing indicator light activity function).
To adjust the brightness of the multifunction
meter displays and tachometer
1. Turn the key to “OFF”.
2. Push and hold the “SELECT” button.
3. Turn the key to “ON”, and then release the
“SELECT” button after five seconds.
1-10
FEATURES
4. Push the “RESET” button to select the
desired brightness level.
5. Push the “SELECT” button to confirm the
selected brightness level. The control
mode changes to the shift timing indicator
light activity function.
To set the shift timing indicator light activity
function
1. Push the “RESET” button to select one of
the following indicator light activity settings:
• The indicator light will stay on when activated. (This setting is selected when the
indicator light stays on.)
• The indicator light will flash when activated.
(This setting is selected when the indicator
light flashes four times per second.)
• The indicator light is deactivated; in other
words, it will not come on or flash. (This
setting is selected when the indicator light
flashes once every two seconds.)
2. Push the “SELECT” button to confirm the
selected indicator light activity. The control
mode changes to the shift timing indicator
light activation function.ry two seconds.)
To set the shift timing indicator light activation
function
NOTE:
The shift timing indicator light activation function can be set between 7000 r/min and 15000
r/min. From 7000 r/min to 12000 r/min, the indicator light can be set in increments of 500 r/
min. From 12000 r/min to 15000 r/min, the indicator light can be set in increments of 200 r/
min.
• Be sure to set the deactivation function to a
higher engine speed than for the activation
function, otherwise the shift timing indicator
light will remain deactivated.
1. Push the “RESET” button to select the
desired engine speed for deactivating the
indicator light.
2. Push the “SELECT” button to confirm the
selected engine speed. The control mode
changes to the shift timing indicator light
brightness function.
To adjust the shift timing indicator light brightness
1. Push the “RESET” button to select the
desired indicator light brightness level.
2. Push the “SELECT” button to confirm the
selected indicator light brightness level.
The right display will return to the odometer
or tripmeter mode.
1. Push the “RESET” button to select the
desired engine speed for activating the
indicator light.
2. Push the “SELECT” button to confirm the
selected engine speed. The control mode
changes to the shift timing indicator light
deactivation function.
To set the shift timing indicator light deactivation function
NOTE:
• The shift timing indicator light deactivation
function can be set between 7000 r/min and
15000 r/min. From 7000 r/min to 12000 r/
min, the indicator light can be set in increments of 500 r/min. From 12000 r/min to
15000 r/min, the indicator light can be set in
increments of 200 r/min.
1-11
EAS20180
IMPORTANT INFORMATION
EAS20190
PREPARATION FOR REMOVAL AND DISASSEMBLY
1. Before removal and disassembly, remove
all dirt, mud, dust and foreign material.
2. Use only the proper tools and cleaning
equipment.
Refer to "SPECIAL TOOLS" on page 1-15.
3. When disassembling, always keep mated
parts together. This includes gears, cylinders, pistons and other parts that have
been “mated” through normal wear. Mated
parts must always be reused or replaced
as an assembly.
IMPORTANT INFORMATION
EAS20210
GASKETS, OIL SEALS AND O-RINGS
1. When overhauling the engine, replace all
gaskets, seals and O-rings. All gasket surfaces, oil seal lips and O-rings must be
cleaned.
2. During reassembly, properly oil all mating
parts and bearings and lubricate the oil
seal lips with grease.
4. During disassembly, clean all of the parts
and place them in trays in the order of disassembly. This will speed up assembly and
allow for the correct installation of all parts.
5. Keep all parts away from any source of fire.
EAS20200
REPLACEMENT PARTS
Use only genuine Yamaha parts for all replacements. Use oil and grease recommended by
Yamaha for all lubrication jobs. Other brands
may be similar in function and appearance, but
inferior in quality.
1. Oil
2. Lip
3. Spring
4. Grease
EAS20220
LOCK WASHERS/PLATES AND COTTER
PINS
After removal, replace all lock washers/plates
“1” and cotter pins. After the bolt or nut has
been tightened to specification, bend the lock
tabs along a flat of the bolt or nut.
1-12
EAS20230
BEARINGS AND OIL SEALS
Install bearings “1” and oil seals “2” so that the
manufacturer’s marks or numbers are visible.
When installing oil seals, lubricate the oil seal
lips with a light coat of lithium-soap-based
grease. Oil bearings liberally when installing, if
appropriate.
IMPORTANT INFORMATION
ECA13300
CAUTION:
Do not spin the bearing with compressed
air because this will damage the bearing
surfaces.
EAS20240
CIRCLIPS
Before reassembly, check all circlips carefully
and replace damaged or distorted circlips.
Always replace piston pin clips after one use.
When installing a circlip “1”, make sure the
sharp-edged corner “2” is positioned opposite
the thrust “3” that the circlip receives.
1-13
EAS20250
CHECKING THE CONNECTIONS
Check the leads, couplers, and connectors for
stains, rust, moisture, etc.
1. Disconnect:
• Lead
• Coupler
• Connector
2. Check:
• Lead
• Coupler
• Connector
Moisture → Dry with an air blower.
Rust/stains → Connect and disconnect
several times.
CHECKING THE CONNECTIONS
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
NOTE:
• If there is no continuity, clean the terminals.
• When checking the wire harness, perform
steps (1) to (3).
• As a quick remedy, use a contact revitalizer
available at most part stores.
3. Check:
• All connections
Loose connection → Connect properly.
NOTE:
If the pin “1” on the terminal is flattened, bend
it up.
4. Connect:
• Lead
• Coupler
• Connector
NOTE:
Make sure all connections are tight.
5. Check:
•Continuity
(with the pocket tester)
1-14
SPECIAL TOOLS
EAS20260
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 inappropriate 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.
NOTE:
• For U.S.A. and Canada, use part number starting with “YM-”, “YU-”, or “ACC-”.
• For others, use part number starting with “90890-”.
Tool name/Tool No. Illustration
Piston pin puller set
90890-01304
Piston pin puller
YU-01304
Radiator cap tester
90890-01325
Radiator pressure tester
YU-24460-01
Radiator cap tester adapter
90890-01352
Radiator pressure tester adapter
YU-33984
Steering nut wrench
90890-01403
Spanner wrench
YU-33975
Reference
pages
5-71
6-3
6-3
3-28, 4-60
Damper rod holder
90890-01423
Damping rod holder
YM-01423
Oil filter wrench
90890-01426
YU-38411
4-52, 4-53
3-12
1-15
SPECIAL TOOLS
Tool name/Tool No. Illustration
Rod holder
90890-01434
Damper rod holder double ended
YM-01434
Rod puller
90890-01437
Universal damping rod bleeding tool set
YM-A8703
Rod puller attachment (M12)
90890-01435
Universal damping rod bleeding tool set
YM-A8703
Fork spring compressor
90890-01441
YM-01441
Reference
pages
4-51, 4-56
4-55, 4-56
4-55, 4-56
4-51, 4-56
Fork seal driver
90890-01442
Adjustable fork seal driver (36–46 mm)
YM-01442
Vacuum gauge
90890-03094
Carburetor synchronizer
YU-44456
Compression gauge
90890-03081
Engine compression tester
YU-33223
Extension
90890-04136
4-54
3-7
3-10
3-10
1-16
SPECIAL TOOLS
Tool name/Tool No. Illustration
Valve spring compressor
90890-04019
YM-04019
Valve spring compressor attachment
90890-04108
Valve spring compressor adapter (22 mm)
YM-04108
Middle driven shaft bearing driver
90890-04058
Bearing driver (40 mm)
YM-04058
Mechanical seal installer
90890-04078
Water pump seal installer
YM-33221-A
Reference
pages
5-23, 5-29
5-23, 5-29
6-11
6-11
Universal clutch holder
90890-04086
YM-91042
Valve guide remover (ø5)
90890-04097
Valve guide remover (5.0 mm)
YM-04097
Valve guide remover (ø4.5)
90890-04116
Valve guide remover (4.5 mm)
YM-04116
Valve guide installer (ø5)
90890-04098
Valve guide installer (5.0 mm)
YM-04098
5-47, 5-51
5-25
5-25
5-25
1-17
SPECIAL TOOLS
Tool name/Tool No. Illustration
Valve guide installer (ø4.5)
90890-04117
Valve guide installer (4.5 mm)
YM-04117
Valve guide reamer (ø5)
90890-04099
Valve guide reamer (5.0 mm)
YM-04099
Valve guide reamer (ø4.5)
90890-04118
Valve guide reamer (4.5mm)
YM-04118
Ignition checker
90890-06754
Opama pet-4000 spark checker
YU-34487
Reference
pages
5-25
5-25
5-25
8-84
Yamaha bond No.1215
(Three Bond No.1215)
90890-85505
Pivot shaft wrench
90890-01471
Frame spanner socket
YM-01471
Pivot shaft wrench adapter
90890-01476
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
5-67, 6-11
5-7
5-7
1-14, 5-41, 8-75,
8-76, 8-77, 8-80,
8-81, 8-82, 8-83,
8-84, 8-85, 8-86,
8-87, 8-88, 8-89,
8-90, 8-91, 8-92
1-18
SPECIAL TOOLS
Tool name/Tool No. Illustration
Oil pressure gauge adapter
90890-03139
Valve lapper
90890-04101
Valve lapping tool
YM-A8998
Fuel pressure adapter
90890-03176
YM-03176
Pressure gauge
90890-03153
YU-03153
Reference
pages
3-13
3-5
7-6
3-13, 7-6
Camshaft wrench
90890-04143
YM-04143
Ring nut wrench
90890-01507
YM-01507
Damper rod holder (22 mm)
90890-01365
5-11, 5-16
4-67, 4-69
4-68, 4-69
1-19
SPECIFICATIONS
GENERAL SPECIFICATIONS ......................................................................2-1
ENGINE SPECIFICATIONS..........................................................................2-2
CHASSIS SPECIFICATIONS........................................................................2-8
ELECTRICAL SPECIFICATIONS...............................................................2-10
TIGHTENING TORQUES............................................................................2-12
GENERAL TIGHTENING TORQUE SPECIFICATIONS....................... 2-12
ENGINE TIGHTENING TORQUES ......................................................2-13
CHASSIS TIGHTENING TORQUES ....................................................2-17
LUBRICATION POINTS AND LUBRICANT TYPES ..................................2-20
ENGINE ................................................................................................2-20
CHASSIS ..............................................................................................2-21
2
LUBRICATION SYSTEM CHART AND DIAGRAMS .................................2-23
ENGINE OIL LUBRICATION CHART ...................................................2-23
LUBRICATION DIAGRAMS ..................................................................2-25
COOLING SYSTEM DIAGRAMS ...............................................................2-35
CABLE ROUTING ......................................................................................2-39
GENERAL SPECIFICATIONS
EAS20280
GENERAL SPECIFICATIONS
Model
Model 4C84 (U.S.A.)
Dimensions
Overall length 2060 mm (81.1 in)
Overall width 720 mm (28.3 in)
Overall height 1110 mm (43.7 in)
Seat height 835 mm (32.9 in)
Wheelbase 1415 mm (55.7 in)
Ground clearance 135 mm (5.31 in)
Minimum turning radius 3400 mm (133.9 in)
Weight
With oil and fuel 200 kg (441 lb)
Maximum load 195 kg (430 lb)
4C85 (California)
2-1
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