Yamaha YZF-R1P YZF-R1PC Service Manual – PDF DOWNLOAD

Description

Yamaha YZF-R1P YZF-R1PC Service Manual

DESCRIPTION:

Yamaha YZF-R1P YZF-R1PC Service Manual 

FOREWORD:

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.

TABLE OF CONTENTS:

Yamaha YZF-R1P YZF-R1PC Service Manual 

CHAPTER 1
GENERAL INFORMATION
MOTORCYCLE IDENTIFICATION 1-1
VEHICLE IDENTIFICATION NUMBER 1-1
MODEL LABEL 1-1
FEATURES 1-2
OUTLINE OF FI SYSTEM 1-2
FI SYSTEM 1-3
COMPONENTS 1-5
FUEL INJECTION SYSTEM 1-16
THREE-WAY CATALYTIC CONVERTER SYSTEM 1-19
INSTRUMENT FUNCTION 1-20
IMPORTANT INFORMATION 1-23
PREPARATION FOR REMOVAL AND DISASSEMBLY 1-23
REPLACEMENT PARTS 1-23
GASKETS, OIL SEALS AND O-RINGS 1-23
LOCK WASHERS/PLATES AND COTTER PINS 1-24
BEARINGS AND OIL SEALS 1-24
CIRCLIPS 1-24
CHECKING THE CONNECTIONS 1-25
SPECIAL TOOLS 1-26
CHAPTER 2
SPECIFICATIONS
GENERAL SPECIFICATIONS 2-1
ENGINE SPECIFICATIONS 2-2
CHASSIS SPECIFICATIONS 2-11
ELECTRICAL SPECIFICATIONS 2-15
CONVERSION TABLE 2-17
TIGHTENING TORQUES 2-17
GENERAL TIGHTENING TORQUE SPECIFICATIONS 2-17
ENGINE TIGHTENING TORQUES 2-18
CHASSIS TIGHTENING TORQUES 2-21
LUBRICATION POINTS AND LUBRICANT TYPES 2-23
ENGINE 2-23
CHASSIS 2-24
COOLING SYSTEM DIAGRAMS 2-25
ENGINE OIL LUBRICATION CHART 2-29
LUBRICATION DIAGRAMS 2-30
CABLE ROUTING 2-35
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 TANK 3-4
REMOVING THE FUEL TANK 3-5
REMOVING THE FUEL PUMP 3-5
INSTALLING THE FUEL PUMP 3-6
INSTALLING THE FUEL HOSE 3-6
COWLINGS 3-7
AIR FILTER CASE 3-8
ENGINE 3-9
ADJUSTING THE VALVE CLEARANCE 3-9
SYNCHRONIZING THE THROTTLE BODIES 3-14
ADJUSTING THE ENGINE IDLING SPEED 3-16
ADJUSTING THE THROTTLE CABLE FREE PLAY 3-17
CHECKING THE SPARK PLUGS 3-19
MEASURING THE COMPRESSION PRESSURE 3-20
CHECKING THE ENGINE OIL LEVEL 3-23
CHANGING THE ENGINE OIL 3-24
ADJUSTING THE CLUTCH CABLE FREE PLAY 3-26
REPLACING THE AIR FILTER ELEMENT 3-28
CHECKING THE FUEL AND BREATHER HOSES 3-29
CHECKING THE CRANKCASE BREATHER HOSE 3-29
CHECKING THE EXHAUST SYSTEM 3-30
ADJUSTING THE EXUP CABLES 3-31
CHECKING THE COOLANT LEVEL 3-32
CHECKING THE COOLING SYSTEM 3-33
CHANGING THE COOLANT 3-34
CHASSIS 3-37
ADJUSTING THE FRONT BRAKE 3-37
ADJUSTING THE REAR BRAKE 3-38
CHECKING THE BRAKE FLUID LEVEL 3-39
CHECKING THE FRONT AND REAR BRAKE PADS 3-40
ADJUSTING THE REAR BRAKE LIGHT SWITCH 3-40
CHECKING THE FRONT AND REAR BRAKE HOSES 3-41
BLEEDING THE HYDRAULIC BRAKE SYSTEM 3-41
ADJUSTING THE SHIFT PEDAL 3-43
ADJUSTING THE DRIVE CHAIN SLACK 3-43
LUBRICATING THE DRIVE CHAIN 3-45
CHECKING AND ADJUSTING THE STEERING HEAD 3-45
CHECKING THE FRONT FORK 3-48
ADJUSTING THE FRONT FORK LEGS 3-49
ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY 3-51
CHECKING THE TIRES 3-53
CHECKING THE WHEELS 3-56
CHECKING AND LUBRICATING THE CABLES 3-57
LUBRICATING THE LEVERS AND PEDALS 3-57
LUBRICATING THE SIDESTAND 3-57
LUBRICATING THE REAR SUSPENSION 3-57
ELECTRICAL SYSTEM 3-58
CHECKING AND CHARGING THE BATTERY 3-58
CHECKING THE FUSES 3-63
REPLACING THE HEADLIGHT BULBS 3-65
ADJUSTING THE HEADLIGHT BEAM 3-66
CHAPTER 4
CHASSIS
FRONT WHEEL AND BRAKE DISCS 4-1
FRONT WHEEL 4-2
REMOVING THE FRONT WHEEL 4-3
CHECKING THE FRONT WHEEL 4-3
CHECKING THE BRAKE DISCS 4-5
INSTALLING THE FRONT WHEEL 4-6
ADJUSTING THE FRONT WHEEL STATIC BALANCE 4-7
REAR WHEEL AND BRAKE DISC 4-9
REAR WHEEL 4-10
REMOVING THE REAR WHEEL 4-12
CHECKING THE REAR WHEEL 4-13
CHECKING THE REAR WHEEL DRIVE HUB 4-13
CHECKING AND REPLACING THE REAR WHEEL SPROCKET 4-14
INSTALLING THE REAR WHEEL 4-14
ADJUSTING THE REAR WHEEL STATIC BALANCE 4-15
FRONT AND REAR BRAKES 4-16
FRONT BRAKE PADS 4-16
REAR BRAKE PADS 4-17
REPLACING THE FRONT BRAKE PADS 4-18
REPLACING THE REAR BRAKE PADS 4-21
FRONT BRAKE MASTER CYLINDER 4-23
REAR BRAKE MASTER CYLINDER 4-26
DISASSEMBLING THE FRONT BRAKE MASTER CYLINDER 4-28
DISASSEMBLING THE REAR BRAKE MASTER CYLINDER 4-28
CHECKING THE FRONT
AND REAR BRAKE MASTER CYLINDERS 4-29
ASSEMBLING AND INSTALLING
THE FRONT BRAKE MASTER CYLINDER 4-30
ASSEMBLING THE REAR BRAKE MASTER CYLINDER 4-32
FRONT BRAKE CALIPERS 4-34
REAR BRAKE CALIPER 4-36
DISASSEMBLING THE FRONT BRAKE CALIPERS 4-38
DISASSEMBLING THE REAR BRAKE CALIPER 4-39
CHECKING THE FRONT AND REAR BRAKE CALIPERS 4-40
ASSEMBLING AND INSTALLING THE FRONT BRAKE CALIPERS 4-41
ASSEMBLING AND INSTALLING THE REAR BRAKE CALIPER 4-43
FRONT FORK 4-45
REMOVING THE FRONT FORK LEGS 4-48
DISASSEMBLING THE FRONT FORK LEGS 4-48
CHECKING THE FRONT FORK LEGS 4-50
ASSEMBLING THE FRONT FORK LEGS 4-51
INSTALLING THE FRONT FORK LEGS 4-55
HANDLEBARS 4-56
REMOVING THE HANDLEBARS 4-58
CHECKING THE HANDLEBARS 4-58
INSTALLING THE HANDLEBARS 4-58
STEERING HEAD 4-61
REMOVING THE LOWER BRACKET 4-63
CHECKING THE STEERING HEAD 4-63
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 ASSEMBLY 4-67
CHECKING THE REAR SHOCK ABSORBER ASSEMBLY 4-68
INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY 4-68
SWINGARM AND DRIVE CHAIN 4-69
REMOVING THE SWINGARM 4-71
REMOVING THE DRIVE CHAIN 4-72
CHECKING THE SWINGARM 4-72
CHECKING THE DRIVE CHAIN 4-73
INSTALLING THE SWINGARM 4-75
CHAPTER 5
OVERHAULING THE ENGINE
ENGINE 5-1
DRIVE SPROCKET 5-1
EXHAUST PIPE 5-2
LEADS AND HOSES 5-4
ENGINE 5-6
INSTALLING THE ENGINE 5-7
CAMSHAFT 5-8
CYLINDER HEAD COVERS 5-8
CAMSHAFTS 5-9
REMOVING THE CAMSHAFTS 5-11
CHECKING THE CAMSHAFTS 5-12
CHECKING THE TIMING CHAIN, CAMSHAFT SPROCKETS,
AND TIMING CHAIN GUIDES 5-14
CHECKING THE TIMING CHAIN TENSIONER 5-15
INSTALLING THE CAMSHAFTS 5-15
CYLINDER HEAD 5-19
REMOVING THE CYLINDER HEAD 5-20
CHECKING THE CYLINDER HEAD 5-20
INSTALLING THE CYLINDER HEAD 5-21
VALVES AND VALVE SPRINGS 5-22
REMOVING THE VALVES 5-24
CHECKING THE VALVES AND VALVE GUIDES 5-25
CHECKING THE VALVE SEATS 5-27
CHECKING THE VALVE SPRINGS 5-28
CHECKING THE VALVE LIFTERS 5-29
INSTALLING THE VALVES 5-29
GENERATOR 5-32
REMOVING THE GENERATOR 5-33
INSTALLING THE GENERATOR 5-33
PICKUP COIL 5-36
REMOVING THE PICKUP COIL ROTOR 5-38
INSTALLING THE PICKUP COIL ROTOR 5-38
CLUTCH 5-40
CLUTCH COVER 5-40
PULL LEVER SHAFT 5-41
CLUTCH 5-42
REMOVING THE CLUTCH 5-44
CHECKING THE FRICTION PLATES 5-44
CHECKING THE CLUTCH PLATES 5-45
CHECKING THE CLUTCH HOUSING 5-45
CHECKING THE CLUTCH BOSS 5-45
CHECKING THE PRESSURE PLATE 5-46
CHECKING THE PULL LEVER SHAFT AND PULL ROD 5-46
CHECKING THE STARTER CLUTCH 5-46
INSTALLING THE CLUTCH 5-47
SHIFT SHAFT 5-49
SHIFT SHAFT AND STOPPER LEVER 5-49
CHECKING THE SHIFT SHAFT 5-50
CHECKING THE STOPPER LEVER 5-50
INSTALLING THE SHIFT SHAFT 5-50
OIL PAN AND OIL PUMP 5-51
OIL PUMP 5-53
REMOVING THE OIL PAN 5-54
CHECKING THE OIL PUMP 5-54
CHECKING THE RELIEF VALVE 5-55
CHECKING THE OIL DELIVERY PIPES 5-55
CHECKING THE OIL STRAINER 5-55
ASSEMBLING THE OIL PUMP 5-56
INSTALLING THE OIL PUMP 5-56
INSTALLING THE OIL STRAINER 5-57
INSTALLING THE OIL PAN 5-57
CRANKCASE 5-58
DISASSEMBLING THE CRANKCASE 5-60
CHECKING THE CRANKCASE 5-61
CHECKING THE BEARINGS AND OIL SEALS 5-61
CHECKING THE SPROCKET AND CHAINS 5-61
ASSEMBLING THE CRANKCASE 5-62
CONNECTING RODS AND PISTONS 5-64
REMOVING THE CONNECTING RODS AND PISTONS 5-65
REMOVING THE CRANKSHAFT ASSEMBLY 5-66
CHECKING THE CYLINDER AND PISTONS 5-66
CHECKING THE PISTON RINGS 5-68
CHECKING THE PISTON PINS 5-69
CHECKING THE BIG END BEARINGS 5-69
INSTALLING THE CONNECTING ROD AND PISTON 5-72
CRANKSHAFT 5-76
CHECKING THE CRANKSHAFT 5-77
CHECKING THE CRANKSHAFT JOURNAL BEARINGS 5-77
INSTALLING THE CRANKSHAFT 5-80
TRANSMISSION 5-81
REMOVING THE TRANSMISSION 5-87
CHECKING THE SHIFT FORKS 5-87
CHECKING THE SHIFT DRUM ASSEMBLY 5-88
CHECKING THE TRANSMISSION 5-88
INSTALLING THE TRANSMISSION 5-89
CHAPTER 6
COOLING SYSTEM
RADIATOR 6-1
CHECKING THE RADIATOR 6-3
INSTALLING THE RADIATOR 6-4
OIL COOLER 6-5
CHECKING THE OIL COOLER 6-6
INSTALLING THE OIL COOLER 6-6
THERMOSTAT 6-7
CHECKING THE THERMOSTAT 6-10
ASSEMBLING THE THERMOSTAT ASSEMBLY 6-11
INSTALLING THE THERMOSTAT ASSEMBLY 6-11
WATER PUMP 6-12
DISASSEMBLING THE WATER PUMP 6-14
CHECKING THE WATER PUMP 6-14
ASSEMBLING THE WATER PUMP 6-15
CHAPTER 7
FUEL INJECTION SYSTEM
FUEL INJECTION SYSTEM 7-1
WIRING DIAGRAM 7-2
ECU’S SELF-DIAGNOSTIC FUNCTION 7-3
SUBSTITUTE CHARACTERISTICS OPERATION CONTROL
(FAIL-SAFE ACTION) 7-4
FAIL-SAFE ACTIONS TABLE 7-4
TROUBLESHOORING CHART 7-5
DIAGNOSTIC MODE 7-6
TROUBLESHOOTING DETAILS 7-12
THROTTLE BODIES 7-29
CHECKING THE INJECTOR 7-33
CHECKING THE THROTTLE BODY 7-33
CHECKING THE PRESSURE REGULATOR 7-34
CHECKING THE FUEL PUMP
AND PRESSURE REGULATOR OPERATION 7-34
CHECKING AND ADJUSTING
THE THROTTLE POSITION SENSOR 7-35
AIR INDUCTION SYSTEM 7-37
AIR INDUCTION 7-37
AIR CUT-OFF VALVE 7-37
AIR INDUCTION SYSTEM DIAGRAMS 7-38
CHECKING THE AIR INDUCTION SYSTEM 7-39
CHAPTER 8
ELECTRICAL
ELECTRICAL COMPONENTS 8-1
CHECKING SWITCH CONTINUITY 8-3
CHECKING THE SWITCHES 8-4
CHECKING THE BULBS AND BULB SOCKETS 8-5
TYPES OF BULBS 8-5
CHECKING THE CONDITION OF THE BULBS 8-6
CHECKING THE CONDITION OF THE BULB SOCKETS 8-7
CHECKING THE LEDs 8-7
IGNITION SYSTEM 8-8
CIRCUIT DIAGRAM 8-8
TROUBLESHOOTING 8-9
ELECTRIC STARTING SYSTEM 8-13
CIRCUIT DIAGRAM 8-13
STARTING CIRCUIT CUT-OFF SYSTEM OPERATION 8-14
TROUBLESHOOTING 8-15
STARTER MOTOR 8-18
CHECKING THE STARTER MOTOR 8-20
ASSEMBLING THE STARTER MOTOR 8-21
CHARGING SYSTEM 8-22
CIRCUIT DIAGRAM 8-22
TROUBLESHOOTING 8-23
LIGHTING SYSTEM 8-25
CIRCUIT DIAGRAM 8-25
TROUBLESHOOTING 8-27
CHECKING THE LIGHTING SYSTEM 8-29
SIGNALING SYSTEM 8-32
CIRCUIT DIAGRAM 8-32
TROUBLESHOOTING 8-34
CHECKING THE SIGNALING SYSTEM 8-34
COOLING SYSTEM 8-41
CIRCUIT DIAGRAM 8-41
TROUBLESHOOTING 8-42
FUEL PUMP SYSTEM 8-45
CIRCUIT DIAGRAM 8-45
FUEL PUMP SYSTEM 8-46
TROUBLESHOOTING 8-47
CHECKING THE FUEL PUMP 8-49
CHAPTER 9
TROUBLESHOOTING
STARTING FAILURES 9-1
ENGINE 9-1
FUEL SYSTEM 9-1
ELECTRICAL SYSTEMS 9-2
INCORRECT ENGINE IDLING SPEED 9-2
ENGINE 9-2
FUEL SYSTEM 9-2
ELECTRICAL SYSTEMS 9-2
POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE 9-3
ENGINE 9-3
FUEL SYSTEM 9-3
FAULTY GEAR SHIFTING 9-3
SHIFTING IS DIFFICULT 9-3
SHIFT PEDAL DOES NOT MOVE 9-3
JUMPS OUT OF GEAR 9-3
FAULTY CLUTCH 9-3
CLUTCH SLIPS 9-3
CLUTCH DRAGS 9-3
OVERHEATING 9-4
ENGINE 9-4
COOLING SYSTEM 9-4
FUEL SYSTEM 9-4
CHASSIS 9-4
ELECTRICAL SYSTEMS 9-4
OVERCOOLING 9-4
COOLING SYSTEM 9-4
POOR BRAKING PERFORMANCE 9-4
FAULTY FRONT FORK LEGS 9-5
LEAKING OIL 9-5
MALFUNCTION 9-5
UNSTABLE HANDLING 9-5
FAULTY LIGHTING OR SIGNALING SYSTEM 9-6
HEADLIGHT DOES NOT COME ON 9-6
HEADLIGHT BULB BURNT OUT 9-6
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 SLOWLY 9-6
TURN SIGNAL REMAINS LIT 9-6
TURN SIGNAL BLINKS QUICKLY 9-6
HORN DOES NOT SOUND 9-6

YAMAHA YZF-R1P YZF-R1PC SERVICE MANUAL – PDF DOWNLOAD:

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