Yamaha YZF-R1 98 User manual

SERVICEMANUAL
YZF-R1 4XV1-AE1
’98

EB000000
YZF - R1
SERVICE MANUAL
 1997 by Yamaha Motor Co., Ltd.
First edition, October 1997
All rights reserved. Any reproduction or
unauthorized use without the written
permission of Yamaha Motor Co., Ltd.
is expressly prohibited.

EB001000
NOTICE
This manual was produced by the Yamaha M otor Com pany, 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 w ho uses this book to perform maintenance and
repairs on Yam aha vehicles should have a basic understanding of m echanics and the tech-
niques to repair these types of vehicles. Repair and maintenance work attem pted by anyone
without this know ledge is likely to render the vehicle unsafe and unfit for use.
Yamaha Motor Company, Ltd. is continually striving to im prove all of its m odels. M odifica-
tions and significant changes in specifications or procedures will be forw arded to all autho-
rized Yamaha dealers and will appear in future editions of this m anual w here applicable.
NOTE:
Designs and specifications are subject to change without notice.
EB002000
IMPORTANT MANUAL INFORMATION
Particularly im portant information is distinguished in this manual by the follow ing.
The Safety Alert Sym bol m eans ATTENTION! BECOME ALERT! YOUR
SAFETY IS INVOLVED!
Failure to follow WARNING instructions could result in severe injury or
death to the m otorcycle operator, a bystander or a person checking or
repairing the m otorcycle.
A CAUTION indicates special precautions that must be taken to avoid
damage to the motorcycle.
A NOTE provides key information to make procedures easier or clearer.
WARNING
CAUTION:
NOTE:

EB003000
HOW TO USE THIS MANUAL
This manual is intended as a handy, easy-to-read reference book for the mechanic. Compre-
hensive explanations of all installation, rem oval, disassembly, assembly, repair and check
procedures are laid out w ith the individual steps in sequential order.
1 The manual is divided into chapters. An abbreviation and sym bol in the upper right corner
of each page indicate the current chapter.
Refer to “ SYMBOLS” .
2 Each chapter is divided into sections. The current section title is shown at the top of each
page, except in Chapter 3 (“ PERIODIC CHECKS AND ADJUSTM ENTS” ), w here the sub-sec-
tion title(-s) appears.
3 Sub-section titles appear in sm aller print than the section title.
4 To help identify parts and clarify procedure steps, there are exploded diagram s at the start
of each removal and disassem bly section.
5 Numbers are given in the order of the jobs in the exploded diagram. A circled number indi-
cates a disassembly step.
6 Symbols indicate parts to be lubricated or replaced.
Refer to “ SYMBOLS” .
7 A job instruction chart accom panies the exploded diagram, providing the order of jobs,
names of parts, notes in jobs, etc.
8 Jobs requiring m ore information (such as special tools and technical data) are described
sequentially.

EB004000
SYMBOLS
The following symbols are not relevant to
every vehicle.
Symbols 1 to 9 indicate the subject of
each chapter.
1 General information
2 Specifications
3 Periodic checks and adjustm ents
4 Engine
5 Cooling system
6 Carburetor(-s)
7 Chassis
8 Electrical system
9 Troubleshooting
Symbols 0 to G indicate the follow ing.
0 Serviceable with engine mounted
A Filling fluid
B Lubricant
C Special tool
D Tightening torque
E Wear lim it, clearance
F Engine speed
G Electrical data
Symbols H to M in the exploded diagram s
indicate the types of lubricants and lubrica-
tion points.
H Engine oil
I Gear oil
J Molybdenum disulfide oil
K Wheel bearing grease
L Lithium soap base grease
M Molybdenum disulfide grease
Symbols N to O in the exploded diagram s
indicate the follow ing.
NApply locking agent (LOCTITE)
OReplace the part
12
34
56
78
90
AB
CD
EFG
HIJ
KLM
NO
GEN
INFO
SPEC
CHK
ADJ ENG
COOL CARB
CHAS
–+
ELEC
TRBL
SHTG
T
R
.
.
GM
E
BLS M
LT New

CHAPTER TITLES
GENERAL INFORMATION
1
SPECIFICATIONS
SPEC
2
PERIODIC CHECKS AND
ADJUSTMENTS
3
ENGINE
ENG
4
COOLING
COOL
5
CARBURETION
CARB
6
CHASSIS
CHAS
7
ELECTRICAL
ELEC
8
TROUBLESHOOTING
9
GEN
INFO
CHK
ADJ
–+
TRBL
SHTG

GEN
INFO
1

GEN
INFO
CHAPTER 1.
GENERAL INFORMATION
MOTORCYCLE IDENTIFICATION .................................................................1-1
VEHICLE IDENTIFICATION NUMBER ..................................................1-1
MODEL CODE .......................................................................................1-1
IMPORTANT INFORMATION .......................................................................1-2
PREPARATION FOR REMOVAL AND DISASSEMBLY .......................1-2
REPLACEMENT PARTS ........................................................................1-2
GASKETS, OIL SEALS AND O-RINGS ................................................1-2
USING A DYNAMOMETER ..................................................................1-3
LOCK WASHERS/PLATES AND COTTER PINS ..................................1-3
BEARINGS AND OIL SEALS ................................................................1-3
CIRCLIPS ...............................................................................................1-3
CHECKING THE CONNECTIONS .................................................................1-4
SPECIAL TOOLS ...........................................................................................1-5

GEN
INFO

1 - 1
GEN
INFO
MOTORCYCLE IDENTIFICATION
EB100000
GENERAL INFORMATION
MOTORCYCLE IDENTIFICATION
EB100010
VEHICLE IDENTIFICATION NUMBER
The vehicle identification number 1 is
stamped into the right side of the steering
head pipe.
EB100020
MODEL CODE
The model code label 1 is affixed to the
frame. This inform ation will be needed to
order spare parts.