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Introduction • This manual is intended for persons with knowledge and experience of motorcycles. Please refer to the YZF-R1 service manual, which shall be published from YAMAHA MOTOR CO. LTD., for information on part assembly and maintenance. • The design of the YZF-R1 racing kit is based on YZF-R1, according to FIM racing rules, but that does not mean the kit conforms to all competitions. When used in races, riders must mount the YZF-R1 racing kit at their own discretion after checking the rules of competition issued by the sponsor. About Warranty • Please understand that these parts are not covered by warranty. • The Manufacturer does not take any responsibility for problems caused by these parts. Request • These kit parts are intended exclusively for racing purposes. You are strictly requested not to use them on public roads. • The specifications and usage methods of these kit parts along with the contents of this manual are subject to change without notice for improvement. Parts List Symbols • The star mark (*) means that the part is included in the kit set and is a genuine <strong>Yamaha</strong> part. Therefore, you can easily purchase the part at any <strong>Yamaha</strong> part dealer when necessary. • The circle mark (°) means that when needed, the individual part is sold separately to the kit set. No. PART No. PART NAME Q’TY REMARKS ˚ 1 4C8-11181-70 GASKET, CYLINDER HEAD 1 3 t=0.30 mm * 2 5VY-11351-00 GASKET, CYLINDER 1 3 * 3 4C8-11603-00 PISTON RING SET 12 4 5VY-1165A-01 BOLT, CONNECTING ROD SPECIAL 24 Symbol Marks Particularly important information is distinguished in this manual by the following notations. WARNING NOTICE TIP * 5 93450-18157 CIRCLIP 24 This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death. A WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury. A NOTICE indicates special precautions that must be taken to avoid damage to the vehicle or other property. A TIP provides key information to make procedures easier or clearer.
CONTENTS 1 Engine Specifications................................................................................... 1 2 Kit Parts ......................................................................................................... 2 2-1 Installing Engine Parts................................................................................... 2 1. Maintenance Set (14B-MAINT-71)........................................................................ 2 2. Spark Plug Set (14B-R465B-70)........................................................................... 3 3. Head-gasket, Cylinder Gasket .............................................................................. 4 4. Piston Set (14B-116A0-70) ................................................................................... 6 5. Connecting Rod Set (14B-1165B-70) ................................................................... 6 6. Crankshaft (14B-11400-70) .................................................................................. 6 7. High-lift Camshafts................................................................................................ 7 8. Valve Spring Set (14B-A2110-71)......................................................................... 8 9. Air Funnel Set (MGC-021008-00) ......................................................................... 9 10. Secondary Air Funnel Set (MGC-A220909-00) .................................................. 11 11. Throttle Body Clamp Set (14B-1351A-70) .......................................................... 13 12. AIS-plug Set (5VY-A4890-70)............................................................................. 14 13. Clutch Spring Set (4B1-A6330-70) ..................................................................... 16 14. Slipper Clutch Setting Set (4C8-A6377-70) ........................................................ 17 15. Transmission Gear.............................................................................................. 20 16. Mission Maintenance Set (14B-A7000-70) ......................................................... 25 17. Drive Sprockets................................................................................................... 28 18. Sprocket Nut Set (4C8-A7463-70) ...................................................................... 29 2-2 Installing Chassis Parts............................................................................... 30 19. Oil Catcher Tank Set (14B-C1707-70)................................................................ 30 20. Shock Absorber Rear (14B-22210-70) ............................................................... 32 21. Spring Rear Shock.............................................................................................. 35 22. Front Fork ASSY................................................................................................. 36 23. Spring Front Fork ................................................................................................ 40 24. Seat Cushion (13S-24713-70) ............................................................................ 45 25. Front Spare Wheel ASS’Y (4C8-25100-70) ........................................................ 46 26. Rear Spare Wheel ASS’Y (4C8-25300-70)......................................................... 47 27. Throttle Set (14B-C6300-70)............................................................................... 48 28. Throttle Set (14B-C6300-80)............................................................................... 50 29. Tube Guide (5VY-26243-80)............................................................................... 52 2-3 Installing Electrical Parts............................................................................. 53 30. ECU Set (14B-8591A-71) ................................................................................... 53 31. Cable Interface (13S-8533A-70) ......................................................................... 54 32. Wire Harness Set (14B-F2590-70) ..................................................................... 57 33. Headlight Harness Set (14B-F4350-71).............................................................. 67 34. ACM Set (14B-F1400-71) ................................................................................... 69
Page 4 and 5: 3 Tightening Torque List ..........
Page 6 and 7: 2 Kit Parts 2-1 Installing Engine P
Page 8 and 9: 3. Head-gasket, Cylinder Gasket Par
Page 10 and 11: 4. Piston Set (14B-116A0-70) Parts
Page 12 and 13: 8. Valve Spring Set (14B-A2110-71)
Page 14 and 15: 3. Installing the Lever Assembly Se
Page 16 and 17: Ycci System Control You can use the
Page 18 and 19: 12. AIS-plug Set (5VY-A4890-70) Thi
Page 20 and 21: 13. Clutch Spring Set (4B1-A6330-70
Page 22 and 23: (Setting of back torque limiter of
Page 24 and 25: 15. Transmission Gear Parts List No
Page 26 and 27: NOTICE This set contains modified g
Page 28 and 29: - 24 - YZF-R1 Speed List Engine spe
Page 30 and 31: 38 36 29 28 33 27 25 26 29 28 37 35
Page 32 and 33: 17. Drive Sprockets Parts List This
Page 34 and 35: 2-2 Installing Chassis Parts 19. Oi
Page 36 and 37: 20. Shock Absorber Rear (14B-22210-
Page 38 and 39: - 34 - Performance and purpose of k
Page 40 and 41: 22. Front Fork ASSY Parts List No.
Page 42 and 43: - 38 - Performance and purpose of k
Page 44 and 45: 23. Spring Front Fork Parts List No
Page 46 and 47: 5. Remove the push rod and fit the
Page 48 and 49: References Front and rear load chan
Page 50 and 51: 25. Front Spare Wheel ASS’Y (4C8-
Page 52 and 53:
27. Throttle Set (14B-C6300-70) Par
Page 54 and 55:
28. Throttle Set (14B-C6300-80) Par
Page 56 and 57:
29. Tube Guide (5VY-26243-80) Parts
Page 58 and 59:
31. Cable Interface (13S-8533A-70)
Page 60 and 61:
Self-Diagnosis Functions • The EC
Page 62 and 63:
Installing Wire Harness: 1. Remove
Page 64 and 65:
NOTICE The wire from the ACM is des
Page 66 and 67:
Installing Rectifier/Regulator: 1.
Page 68 and 69:
• The switch installed to the STD
Page 70 and 71:
• This harness comes with a coupl
Page 72 and 73:
- 68 -
Page 74 and 75:
3 Tightening Torque List Engine To
Page 76 and 77:
Engine To be tightened Part No. Par
Page 78 and 79:
Page 80 and 81:
Page 82 and 83:
Chassis To be tightened Part No. Pa
Page 84 and 85:
Chassis To be tightened Part No. Pa
Page 86 and 87:
Installing the Crankcase Tightening
Page 88 and 89:
5 YZF-R1 Wiring Diagram - 84 -
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English - Yamaha-Racingparts

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