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Engine To be tightened Part No. Part Name Thread dia. x pitch Implant in CRANKCASE 1 CRANKCASE 1 x CRANKCASE 2 CRANKCASE 1 x CRANKCASE 2 CRANKCASE 1 x CRANKCASE 2 CRANKCASE 1 x CRANKCASE 2 CRANKCASE 1 x CRANKCASE 2 CRANKCASE 1 x CRANKCASE 2 CRANKCASE 1 x CRANKCASE 2 CRANKCASE 1 x CRANKCASE 2 Install COVER, CRANKCASE 1 Install COVER, CHAINCASE 90116-10051 BOLT, STUD 90119-09010 BOLT, HEXAGON WITH WASHER 14B-15156-00 BOLT, CRANK- CASE JOURNAL 95812-08060 BOLT, FLANGE M10 x 1.25 8 TARGETED AT 6 – 9 (0.8 TARGETED AT 0.6-0.9) M9 x 1.25 FOR DETAILS, SEE page 82. M8 x 1.25 24±2 (2.4±0.2) M8 x 1.25 24±2 (2.4±0.2) 90109-06100 BOLT M6 x 1.0 10±2 (1.0±0.2) 90105-06165 BOLT, FLANGE 95812-06060 BOLT, FLANGE 95812-06050 BOLT, FLANGE 95812-06040 BOLT, FLANGE M6 x 1.0 10±2 (1.0±0.2) M6 x 1.0 10±2 (1.0±0.2) M6 x 1.0 10±2 (1.0±0.2) M6 x 1.0 10±2 (1.0±0.2) 90110-06326 BOLT M6 x 1.0 12±2 (1.2±0.2) 90110-06338 BOLT, HEXAGON SOCKET HEAD – 74 – Tightening torque N•m (kgf•m) M6 x 1.0 10±2 (1.0±0.2) Q’ty Remarks 10 APPLY OIL TO BOTH SCREW THREAD AND BEARING SURFACE. CONTROL TORQUE. 10 APPLY OIL TO BOTH SCREW THREAD AND BEARING. REPLACE DURING OVERHAUL. 8 APPLY OIL TO BOTH SCREW THREAD AND BEARING. REPLACE O- RING DUR- ING OVER- HAUL. 2 APPLY OIL TO BOTH SCREW THREAD AND BEARING. 2 APPLY OIL TO BOTH SCREW THREAD AND BEARING. 1 APPLY OIL TO BEARING SURFACE. 6 APPLY OIL TO BOTH SCREW THREAD AND BEARING. 7 APPLY OIL TO BOTH SCREW THREAD AND BEARING. 4 APPLY OIL TO BOTH SCREW THREAD AND BEARING. 8 ACM COVER 3 DRIVE SPROCKET COVER
Engine To be tightened Part No. Part Name Thread dia. Tightening x torque N•m pitch (kgf•m) Install COVER, 90110-06323 BOLT M6 x 1.0 12±2 CRANK 2 (1.2±0.2) Install COVER, 90110-06324 BOLT M6 x 1.0 12±2 CRANK 2 (1.2±0.2) Install COVER1 90110-06331 BOLT M6 x 1.0 12±2 (1.2±0.2) Install COVER1 90110-06323 BOLT M6 x 1.0 12±2 (1.2±0.2) Install COVER 90110-05326 BOLT M6 x 1.0 12±2 (1.2±0.2) Install PLATE, 90149-06071 SCREW M6 x 1.0 10±2 BREATHER (1.0±0.2) Install COVER2 90110-06178 BOLT, HEXAGON SOCKET HEAD Install PROTECTOR to COVER C/C2 Install PLUG to COVER C/C3 Install PLUG to COVER C/C2 MAIN GALLERY 1 MAIN GALLERY 2 Install HOLDER CLUTCH WIRE OIL RETURN PLUG M6 x 1.0 10±2 (1.0±0.2) 90149-06152 SCREW M6 x 1.0 6 – 8 (0.6 – 0.8) 92014-08016 BOLT, BUTTON HEAD 3F9-15362-00 PLUG, OIL LEVEL M8 x 1.25 15±2 (1.5±0.2) M20 x 1.5 1.5±0.5 (0.15±0.05) 36Y-15189-00 PLUG M16 x 1.5 8±2 (0.8±0.2) 4H7-15189-00 PLUG M20 x 1.5 8±2 (0.8±0.2) 90110-06340 BOLT M6 x 1.0 10±2 (1.0±0.2) 90340-12003 PLUG, STRAIGHT SCREW ACM LEAD 90110-06182 BOLT, HEXAGON SOCKET HEAD M12 x 1.0 24±3 (2.4±0.3) M6 x 1.0 10±2 (1.0±0.2) Install STATOR 90149-06128 SCREW M6 x 1.0 14±2 (1.4±0.2) Install BAFFLE 90149-06082 SCREW M6 x 1.0 10±2 PLATE 1 -3 (1.0±0.2) – 75 – Q’ty Remarks 8 CLUTCH COVER 1 CLUTCH COVER 5 CAM CHAIN COVER 1 CAM CHAIN COVER 6 BREATHER COVER 4 2 REED VALVE COVER 2 1 CHECK TIM- ING. 1 TAKE CARE NOT TO OVER- TIGHTEN. 2 TAKE CARE NOT TO OVER- TIGHTEN. 1 TAKE CARE NOT TO OVER- TIGHTEN. 2 1 1 3 TORQUES 10
Page 2 and 3:
Introduction • This manual is int
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 80 and 81: Engine To be tightened Part No. Par
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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