Yamaha YZF-R1 2000 Manual

FOREWORD
This Supplementary Service Manual has been prepared to introduce new service and data for the
YZF-R12000.ForcompleteserviceinformationproceduresitisnecessarytousethisSupplementary
Service Manual together with the following manual.
YZF-R1 SERVICE MANUAL: 4XV1-AE1
YZF-R1 2000
SUPPLEMENTARY
SERVICE MANUAL
1999 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.

NOTE:
WARNING
CAUTION:
EB001000 NOTICE
This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha dealers
andtheirqualifiedmechanics.itisnotpossibletoincludealltheknowledgeofamechanicinonemanu-
al. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles
shouldhaveabasicunderstandingofmechanicsandthetechniquestorepair these types of vehicles.
Repair and maintenance work attempted by anyone without this knowledge is likely to render the ve-
hicle unsafe and unfit for use.
YamahaMotorCompany, Ltd.iscontinuallystrivingtoimproveallof its models. Modifications and sig-
nificant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers
and will appear in future editions of this manual where applicable.
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!
FailuretofollowWARNINGinstructionscouldresultin severeinjuryordeathto
themotorcycleoperator, a bystanderorapersoncheckingorrepairingthe mo-
torcycle.
ACAUTIONindicatesspecialprecautionsthatmustbetakentoavoiddamage
to the motorcycle.
NOTE: A NOTE provides key information to make procedures easier or clearer.

12
4
5
7
8
6
3
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 “SYMBOLS”.
2Each chapter is divided into sections. The current section title is shown at the top of each page,
exceptinChapter3(“PERIODICCHECKSANDADJUSTMENTS”),wherethesub-sectiontitle(-s)ap-
pears.
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 “SYMBOLS”.
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 sequen-
tially.

22
1
3
5
7
9
2
4
8
6
24 25
2321
19 2018
16 1715
1413
11 12
10
GEN
INFO SPEC
ENG
CARB
ELECCHAS
COOL
CHK
ADJ
TRBL
SHTG
EB004000
SYMBOLS
The following symbols are not relevant to every
vehicle.
Symbols 1to 9indicate 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.
10 Serviceable with engine mounted
11 Filling fluid
12 Lubricant
13 Special tool
14 Tightening torque
15 Wear limit, clearance
16 Engine speed
17 Electrical data
Symbols 18 to 23 intheexplodeddiagramsindi-
cate the types of lubricants and lubrication
points.
18 Engine oil
19 Gear oil
20 Molybdenum disulfide oil
21 Wheel bearing grease
22 Lithium soap base grease
23 Molybdenum disulfide grease
Symbols 24 to 25 intheexplodeddiagramsindi-
cate the following.
24 Apply locking agent (LOCTITE)
25 Replace 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)

–1–
GENERAL SPECIFICATIONS SPEC
SPECIFICATIONS
GENERAL SPECIFICATIONS
Item Standard Limit
Dimensions
Overall length
Overall width
Overall height
Seat height
Wheelbase
Minimum ground clearance
Minimum turning radius
2,035 mm
2,095 mm (for AUS)
695 mm
1,105 mm
815 mm
1,395 mm
140 mm
3,400 mm
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Weight
Wet (with oil and a full fuel tank)
Dry (without oil and fuel)
Maximum load (total of cargo, rider,
passenger, and accessories)
194 kg
175 kg
201 kg
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–2–
ENGINE SPECIFICATIONS SPEC
Temp.
ENGINE SPECIFICATIONS
Item Standard Limit
Engine
Engine type
Displacement
Cylinder arrangement
Bore stroke
Compression ratio
Engine idling speed
Vacuum pressure at engine idling
speed
Standard compression pressure
(at sea level)
Liquid-cooled, 4-stroke, DOHC
998 cm3
Forward-inclined parallel 4-cylinder
74 58 mm
11.8 : 1
1,000 1,100 r/min
29.3 kPa (220 mm Hg)
1,450 kPa (14.5 kgf/cm2) at 400 r/min
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Fuel
Recommended fuel
Fuel tank capacity
Total (including reserve)
Reserve only
Regular unleaded gasoline
Unleaded fuel (for AUS)
18 L
3.8 L
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Engine oil
Lubrication system
Recommended oil
Quantity
Total amount
Without oil filter cartridge
replacement
With oil filter cartridge replacement
Oil pressure (hot)
Relief valve opening pressure
Wet sump
SAE20W40SE or SAE10W30SE
3.6 L
2.7 L
2.9 L
45 kPa at 1,100 r/min
(0.45 kgf/cm2at 1,100 r/min)
490 570 kPa (4.9 5.7 kgf/cm2)
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–3–
ENGINE SPECIFICATIONS SPEC
Item Standard Limit
Camshafts
Drive system
Camshaft cap inside diameter
Camshaft journal diameter
Camshaft-journal-to-camshaft-
cap clearance
Intake camshaft lobe dimensions
Measurement A
Measurement B
Measurement C
Exhaust camshaft lobe dimensions
Measurement A
Measurement B
Measurement C
Max. camshaft runout
Chain drive (right)
24.500 24.521 mm
24.459 24.472 mm
0.028 0.062 mm
32.5 32.6 mm
24.95 25.05 mm
7.45 7.65 mm
32.95 33.05 mm
24.95 25.05 mm
7.75 7.95 mm
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32.4 mm
24.85 mm
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32.85 mm
24.85 mm
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0.03 mm

–4–
ENGINE SPECIFICATIONS SPEC
Head Diameter Face Width Seat Width Margin Thickness
Item Standard Limit
Valves, valve seats, valve guides
Valve clearance (cold)
Intake
Exhaust
Valve dimensions
0.11 0.20 mm
0.21 0.25 mm
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Valve head diameter A
Intake
Exhaust
Valve face width B
Intake
Exhaust
Valve seat width C
Intake
Exhaust
Valve margin thickness D
Intake
Exhaust
Valve stem diameter
Intake
Exhaust
Valve guide inside diameter
Intake
Exhaust
Valve-stem-to-valve-guide clearance
Intake
Exhaust
Valve stem runout
Valve seat width
Intake
Exhaust
22.9 23.1 mm
24.4 24.6 mm
1.76 2.90 mm
1.76 2.90 mm
0.9 1.1 mm
0.9 1.1 mm
0.5 0.9 mm
0.5 0.9 mm
3.975 3.990 mm
4.465 4.480 mm
4.000 4.012 mm
4.500 4.512 mm
0.010 0.037 mm
0.020 0.047 mm
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0.9 1.1 mm
0.9 1.1 mm
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3.945 mm
4.43 mm
4.05 mm
4.55 mm
0.08 mm
0.1 mm
0.01 mm
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Connecting rods
Crankshaft-pin-to-big-end-bearing
clearance
Bearing color code
0.031 0.055 mm
–1 = Violet 0 = White 1 = Blue 2 = Black
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–5–
ENGINE SPECIFICATIONS SPEC
Item Standard Limit
Transmission
Transmission type
Primary reduction system
Primary reduction ratio
Secondary reduction system
Secondary reduction ratio
Operation
Gear ratios
1st gear
2nd gear
3rd gear
4nd gear
5th gear
6th gear
Max. main axle runout
Max. drive axle runout
Constant mesh, 6-speed
Spur gear
68/43 (1.581)
Chain drive
43/16 (2.688)
Left-foot operation
35/14 (2.500)
35/19 (1.842)
30/20 (1.500)
28/21 (1.333)
30/25 (1.200)
29/26 (1.115)
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0.08 mm
0.08 mm
Carburetors
Model (manufacturer) quantity
Throttle cable free play (at the
flange of the throttle grip)
ID mark
Main jet
Main air jet
Jet needle
Needle jet
Pilot air jet
Pilot outlet
Pilot jet
Bypass 1
Bypass 2
Bypass 3
Pilot screw turns out
Valve seat size
BDSR40 (MIKUNI) 4
3 5 mm
5JJ1 00
#130
Carburetors 1 and 4: #60
Carburetors 2 and 3: #65
6DEY5-53-3
P-OM
#120
1.0
#15
0.8
0.9
0.8
3.125
1.5
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CHASSIS SPECIFICATIONS SPEC
CHASSIS SPECIFICATIONS
Item Standard Limit
Front tire
Tire type
Size
Model (manufacturer)
Tire pressure (cold)
0 90 kg
90 197 kg
High-speed riding
Min. tire tread depth
Tubeless
120/70 ZR17 (58W)
MEZ3Y FRONT (METZELER)
D207FQ (DUNLOP)
250 kPa (2.5 kg/cm2, 2.5 bar)
250 kPa (2.5 kg/cm2, 2.5 bar)
250 kPa (2.5 kg/cm2, 2.5 bar)
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1.6 mm
Rear tire
Tire type
Size
Model (manufacturer)
Tire pressure (cold)
0 90 kg
90 197 kg
High-speed riding
Min. tire tread depth
Tubeless
190/50 ZR17 (73W)
MEZ3Y (METZELER)/D207N (DUNLOP)
250 kPa (2.5 kg/cm2, 2.5 bar)
290 kPa (2.9 kg/cm2, 2.9 bar)
250 kPa (2.5 kg/cm2, 2.5 bar)
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1.6 mm
Rear brake
Brake type
Operation
Brake pedal position (from the top
of the brake pedal to the bottom of
the rider footrest bracket)
Recommended fluid
Brake discs
Diameter thickness
Min. thickness
Max. deflection
Brake pad lining thickness
Master cylinder inside diameter
Caliper cylinder inside diameter
Single-disc brake
Right-foot operation
35 40 mm
DOT 4
245 5 mm
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5.5 mm
12.7 mm
38.2 mm
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4.5 mm
0.1 mm
0.5 mm
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–7–
CHASSIS SPECIFICATIONS SPEC
Item Standard Limit
Front suspension
Suspension type
Front fork type
Front fork travel
Spring
Free length
Spacer length
Installed length
Spring rate (K1)
Spring stroke (K1)
Optional spring available
Fork oil
Recommended oil
Quantity (each front fork leg)
Level (from the top of the inner
tube, with the inner tube fully
compressed, and without the
fork spring)
Damper adjusting rod locknut
distance
Spring preload adjusting positions
Minimum
Standard
Maximum
Rebound damping adjusting
positions
Minimum*
Standard*
Maximum*
Compression damping adjusting
positions
Minimum*
Standard*
Maximum*
*with the adjusting screw fully turned
in position
Telescopic fork
Coil spring/oil damper
135 mm
255 mm
85 mm
242.4 mm
7.35 N/mm (0.75 kgf/mm)
0 135 mm
No
Suspension oil “01” or equivalent
482 cm3
74 mm
11 mm
8
6
1
11
5
1
9
5
1
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–8–
CHASSIS SPECIFICATIONS SPEC
Item Standard Limit
Rear suspension
Suspension type
Rear shock absorber assembly
type
Rear shock absorber assembly
travel
Spring
Free length
Installed length
Spring rate (K1)
Spring stroke (K1)
Optional spring available
Standard spring preload gas/air
pressure
Spring preload adjusting positions
Minimum
Standard
Maximum
Rebound damping adjusting
positions
Minimum*
Standard*
Maximum*
Compression damping adjusting
positions
Minimum*
Standard*
Maximum*
*with the adjusting screw fully turned
in position
Swingarm (link suspension)
Coil spring/gas-oil damper
65 mm
176 mm
162.5 mm
78.4 N/mm (7.84 kgf/mm)
0 65 mm
No
1,200 kPa (12 kgf/cm2)
1
4
9
11
7
1
11
9
1
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–9–
ELECTRICAL SPECIFICATIONS SPEC
ELECTRICAL SPECIFICATIONS
Item Standard Limit
System voltage 12 V SSS
Ignition system
Ignition system type
Ignition timing
Advanced timing
Advancer type
Pickup coil resistance/color
Transistorized coil ignition unit
model (manufacturer)
Transistorized coil ignition
5_BTDC at 1,050 r/min
55_BTDC at 5,000 r/min
Throttle position sensor and electrical
248 372 W/Gy-B
TNDF54 (DENSO)
SSS
SSS
SSS
SSS
SSS
SSS
Voltage regulator
Regulator type
Model
No-load regulated voltage
Semiconductor short circuit
SH650A-12
14.1 14.9 V
SSS
SSS
SSS
Bulbs (voltage/wattage quantity)
Headlight
Auxiliary light
Tail/brake light
Turn signal light
Meter light
12 V 60 W/55 W 2
12 V 5 W 2
12 V 5 W/21 W 2
12 V 21 W 4
LED
SSS
SSS
SSS
SSS
SSS
Electric starting system
System type
Starter motor
Model (manufacturer)
Power output
Brushes
Overall length
Spring force
Commutator resistance
Commutator diameter
Mica undercut
Constant mesh
5JJ (YAMAHA)
0.75 kW
9.8 mm
4.88 7.32 N (488 732 gf)
0.009 0.011 Ω
24.5 mm
1.5 mm
SSS
SSS
SSS
3.65 mm
SSS
SSS
23.5 mm
SSS
Turn signal relay
Relay type
Model (manufacturer)
Self-cancelling device built-in
Turn signal blinking frequency
Wattage
Full-transistor
FE246BH (DENSO)
No
75 95 cycles/min.
21 W 2
SSS
SSS
SSS
SSS
SSS
Oil level switch model
(manufacturer) 4XV (DENSO) SSS
Fuel pump relay model
(manufacturer) G8R-30Y-M (OMRON) SSS

–10–
ELECTRICAL SPECIFICATIONS SPEC
Item Standard Limit
Thermo unit
Model (manufacturer) 5JJ (NIPPON THERMOSTAT) 
Fuses (amperage quantity)
Main fuse
Headlight fuse
Signaling system fuse
Ignition fuse
Radiator fan fuse
Backup fuse (odometer)
Reserve fuse
30 A 1
20 A 1
20 A 1
15 A 1
10 A 1
10 A 1
30 A 1
20 A 1
15 A 1
10 A 1











–11–
TIGHTENING TORQUES SPEC
NOTE:
TIGHTENING TORQUES
ENGINE TIGHTENING TORQUES
Item Fastener Thread
size
Q’ty Tightening
torque Remarks
size
y
Nm mSkgf
Cylinder head
Cylinder head
Generator rotor
Oil/water pump assembly driven
sprocket cover
Air induction system hose
Crankcase
Crankcase
Crankcase
Crankcase
Ignitor unit
Nut
Cap nut
Bolt
Bolt
Clamp
Bolt
Bolt
Bolt
Bolt
Screw
M10
M10
M10
M6
M7
M9
M6
M6
M8
M5
8
2
1
1
4
10
2
14
2
2
50
65
65
12
4
14
12
24
7
5.0
6.5
6.5
1.2
0.4
1.4
1.2
2.4
0.7
After tightening to 15 Nm (1.5 mSkg), tighten another 45_50_
See NOTE

–12–
TIGHTENING TORQUES SPEC
NOTE:
CHASSIS TIGHTENING TORQUES
Item
Thread size
Tightening
Remarks
Item
Thread
size
Nm mkgf
Remarks
Lower ring nut
Engine mounting
Front mounting bolts
Rear upper mounting bolt
Rear under mounting bolts
Pinch bolts
Exhaust pipe bracket
Rear master cylinder
M30
M10
M10
M10
M8
M8
M8
9
40
55
55
24
24
18
0.9
4.0
5.5
5.5
2.4
2.4
1.8
See 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.