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.

1 - 2
GEN
INFO
IMPORTANT INFORM ATION
EB102000
IMPORTANT INFORM ATION
PREPARATION FOR REMOVAL AND
DISASSEMBLY
1. Before removal and disassembly,
remove all dirt, mud, dust, and foreign
material.
2. Use only the proper tools and cleaning
equipment.
Refer to “ SPECIAL TOOLS” .
3. When disassembling, alw ays keep
mated parts together. This includes
gears, cylinders, pistons and other parts
that have been “ m ated” through norm al
wear. Mated parts must alw ays be
reused or replaced as an assembly.
4. During disassem bly, clean all of the
parts and place them in trays in the
order of disassem bly. This w ill speed up
assembly and allow for the correct
installation of all parts.
5. Keep all parts away from any source of
fire.
EB102010
REPLACEMENT PARTS
Use only genuine Yam aha parts for all
replacements. Use oil and grease recom-
mended by Yamaha for all lubrication jobs.
Other brands may be similar in function
and appearance, but inferior in quality.
EB102020
GASKETS, OIL SEALS AND O-RINGS
1. When overhauling the engine, replace
all gaskets, seals, and O-rings. All gasket
surfaces, oil seal lips, and O-rings m ust
be cleaned.
2. During reassembly, properly oil all m at-
ing parts and bearings and lubricate the
oil seal lips with grease.

1 - 3
GEN
INFO
IMPORTANT INFORM ATION
USING A DYNAMOMETER
The YZF-R1 has a carbon m uffler that may
change color w hen exposed to high tem-
peratures. Therefore, w hen using a dyna-
mometer always use a fan to cool the
muffler.
EB102030
LOCK WASHERS/ PLATES AND COTTER
PINS
After removal, replace all lock washers/
plates 1 and cotter pins. After the bolt or
nut has been tightened to specification,
bend the lock w asher tabs and the cotter
pin ends along a flat of the bolt or nut.
EB102040
BEARINGS AND OIL SEALS
1. Install bearings and oil seals so that the
manufacturer’s m arks or num bers are
visible. When installing oil seals, lubri-
cate the oil seal lips w ith a light coat of
lithium soap base grease. Oil bearings
liberally w hen installing, if appropriate.
1 Oil seal
ACHTUNG:
CAUTION:
Do not spin the bearing w ith com-
pressed air because this will damage
the bearing surfaces.
1 Bearing
EB102050
CIRCLIPS
Before reassembly, check all circlips care-
fully and replace damaged or distorted cir-
clips. Always replace piston pin clips after
one use. When installing a circlip 1 , make
sure that the sharp-edged corner 2 is posi-
tioned opposite the thrust 3 that the circlip
receives.
4 Shaft

1 - 4
GEN
INFO
CHECKING THE CONNECTIONS
EB103000
CHECKING THE CONNECTIONS
Check the leads, couplers, and connectors
for stains, rust, m oisture, etc.
1. Disconnect:
• lead
• coupler
• connector
2. Check:
• lead
• coupler
• connector
Moisture → Dry with an air blower.
Rust/stains → Connect and disconnect
several times.
3. Check:
• all connections
Loose connection → Connect properly.
NOTE:
If the pin 1 on the term inal is flattened,
bend it up.
4. Connect:
• lead
• coupler
• connector
NOTE:
Make sure that all connections are tight.
5. Check:
• continuity
(with the pocket tester)
NOTE:
• If there is no continuity, clean the ter-
minals.
• When checking the w ire harness, per-
form steps (1) to (3).
• As a quick remedy, use a contact revi-
talizer available at m ost part stores.
Pocket tester
90890-03112

1 - 5
GEN
INFO
SPECIAL TOOLS
EB104000
SPECIAL TOOLS
The following special tools are necessary for com plete and accurate tune-up and assembly.
Use only the appropriate special tools as this will help prevent dam age caused by the use of
inappropriate tools or improvised techniques.
When placing an order, refer to the list provided below to avoid any mistakes.
Tool No. Tool name/ Function Illustration
90890-01080
Flywheel puller
This tool is used to rem ove the generator
rotor.
90890-01235
Rotor holding tool
This tool is used to hold the generator
rotor when removing or installing the gen-
erator rotor bolt or pickup coil rotor bolt.
90890-01286
Drive chain cutter
This tool is used to rem ove the drive
chain.
90890-01304
Piston pin puller
This tool is used to rem ove the piston
pins.
90890-01312
Fuel level gauge
This tool is used to m easure the fuel level
in the float chamber.
Radiator cap
tester
90890-01325
Adapter
90890-01352
Radiator cap tester
Adapter
These tools are used to check the cooling
system.
90890-01403
Steering nut wrench
This tool is used to loosen or tighten the
steering stem ring nuts.
90890-01423
Damper rod holder
This tool is used to hold the dam per rod
assembly when loosening or tightening
the damper rod assembly bolt.

1 - 6
GEN
INFO
SPECIAL TOOLS
90890-01426
Oil filter wrench
This tool is needed to loosen or tighten
the oil filter cartridge.
90890-01434
Rod holder
This tool is used to support the dam per
adjusting rod.
Rod puller
90890-01437
Rod puller
attachment
90890-01436
Rod puller
Rod puller attachm ent
These tools are used to pull up the front
fork damper rod.
90890-01441
Fork spring compressor
This tool is used to disassem ble or assem -
ble the front fork legs.
90890-01442
Fork seal driver
This tool is used to install the front fork’s
oil seal and dust seal.
90890-03008
Micrometer
This tool is used to m easure the piston
skirt diameter.
Vacuum gauge
90890-03094
Vacuum gauge
attachment
90890-03060
Vacuum gauge
Vacuum gauge attachm ent
This gauge is used to synchronize the car-
buretors.
Compression
gauge
90890-03081
Adapter
90890-04136
Compression gauge
Adapter
These tools are used to measure engine
compression.
90890-03112
Pocket tester
This tool is used to check the electrical
system.
Tool No. Tool name/ Function Illustration

1 - 7
GEN
INFO
SPECIAL TOOLS
90890-03113
Engine tachometer
This tool is used to check engine speed.
90890-03141
Timing light
This tool is used to check the ignition tim-
ing.
90890-03158
Carburetor angle driver
This tool is used to turn the pilot screw
when adjusting the engine idling speed.
Valve spring com -
pressor
90890-04019
Attachm ent
90890-04108
90890-04114
Valve spring com pressor
Attachment
These tools are used to rem ove or install
the valve assemblies.
Middle driven shaft
bearing driver
90890-04058
Mechanical seal
installer
90890-04078
Middle driven shaft bearing driver
Mechanical seal installer
These tools are used to install the w ater
pump seal.
90890-04086
Clutch holding tool
This tool is used to hold the clutch boss
when removing or installing the clutch
boss nut.
90890-04111
90890-04116
Valve guide rem over
This tool is used to rem ove or install the
valve guides.
90890-04112
90890-04117
Valve guide installer
This tool is used to install the valve
guides.
90890-04113
90890-04118
Valve guide ream er
This tool is used to rebore the new valve
guides.
Tool No. Tool name/ Function Illustration

1 - 8
GEN
INFO
SPECIAL TOOLS
90890-06754
Ignition checker
This tool is used to check the ignition sys-
tem components.
90890-85505
Yamaha bond No. 1215
This bond is used to seal tw o m ating sur-
faces (e.g., crankcase mating surfaces).
Tool No. Tool name/ Function Illustration

SPEC
2

SPEC
CHAPTER 2.
SPECIFICATIONS
GENERAL SPECIFICATIONS ........................................................................2-1
ENGINE SPECIFICATIONS ...........................................................................2-2
CHASSIS SPECIFICATIONS .......................................................................2-11
ELECTRICAL SPECIFICATIONS .................................................................2-15
TIGHTENING TORQUES ............................................................................2-18
GENERAL TIGHTENING TORQUES ..................................................2-18
ENGINE TIGHTENING TORQUES .....................................................2-19
CHASSIS TIGHTENING TORQUES ...................................................2-22
LUBRICATION POINTS AND LUBRICANT TYPES ...................................2-23
ENGINE LUBRICATION POINTS AND LUBRICANT TYPES .............2-23
CHASSIS LUBRICATION POINTS AND LUBRICANT TYPES ...........2-24
OIL FLOW DIAGRAMS ...............................................................................2-25
COOLANT FLOW DIAGRAMS ...................................................................2-29
CABLE ROUTING ........................................................................................2-33

SPEC