Yamaha YZF-R1 Manual

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specications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 Yamaha
part. Therefore, you can easily purchase the part at any Yamaha part dealer when
necessary.
•The circle mark (°) means that although the part is included in the kit set it can also be
purchased individually.
Symbol Marks
Particularly important information is distinguished in this manual by the following notations.
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.
NOTICE
TIP
No. PART No. PART NAME Q’TY REMARKS
˚14C8-11181-70GASKET, CYLINDER
HEAD 1
mm03.0=t3
*25VY-11351-00 GASKET, CYLINDER 13
*34C8-11603-00 PISTON RING SET12
45VY-1165A-01BOLT, CONNECTING ROD
SPECIAL
24
*5 93450-18157 CIRCLIP24

CONTENTS
1 EngineSpecications ................................................................................. 1
2 Kit Parts........................................................................................................ 2
2-1 Installing Electrical Parts..............................................................................2
1. ECU Set (2CR-8591A-71)................................................................................... 2
2. Cable Interface (2CR-8533A-70)........................................................................ 4
3. Wire Harness Set (2CR-F2590-70) .................................................................... 6
4. Headlight Harness Set (2CR-F4350-70) ...........................................................17
5. Repair set (2CR-28130-70, 2KS-28130-70)...................................................... 18
6. CCU COMP. (2KS-85800-70) .......................................................................... 19
2-2 Installing Engine Parts................................................................................24
7. Maintenance Set (2CR-MAINT-71)................................................................... 24
8. Spark Plug Set (14B-R465B-70) ...................................................................... 25
9. Piston Set (2CR-116A0-71)............................................................................... 26
10. Connecting Rod Set (2CR-1165B-70)............................................................... 26
11. Crankshaft (2CR-11400-71) .............................................................................. 26
12. High-lift Camshafts, Cam Sprocket.................................................................. 28
13. Valve Spring Set (2CR-A2110-70).................................................................... 30
14. Air Funnel Set (2CR-1440B-70)........................................................................ 31
15. AIS-plug Set (2CR-A4890-70).......................................................................... 32
16. Screw cap set (2CR-15171-70) ......................................................................... 33
17. Transmission Gear ........................................................................................... 34
18. Mission Maintenance Set (2CR-A7000-70)...................................................... 37
19. Drive Sprockets................................................................................................ 40
20. Sprocket Nut Set (2CR-A7463-70) ....................................................................41
21. Strainer Cover Set (2CR-13400-70) ................................................................. 42
2-3 Installing Chassis Parts ..............................................................................46
22. Spring Rear Shock ........................................................................................... 46
23. Spring Front Fork ............................................................................................. 47
24. Seat Cushion (13S-24713-70)........................................................................... 49
25. Front Spare Wheel ASS’Y (2CR-25100-70) ..................................................... 50
26. Rear Spare Wheel ASS’Y (2CR-25300-70).......................................................51
27. Tube Guide (2CR-26243-70) ............................................................................ 52
3 Tightening Torque List .............................................................................. 53
Tightening the Cylinder Head ................................................................................... 66
Installing the Crankcase ........................................................................................... 67
Procedure to tighten the aluminum bolts .................................................................. 68
Procedure to install the engine ................................................................................. 69
Procedure to install the pivot shaft peripheral parts ................................................. 70
4 Headlight Cord Wiring Diagram ................................................................71
5 YZF-R1 Wiring Diagram ............................................................................ 72

– 1 –
1 EngineSpecications
Spec SBK/JSB STK STD
Displacement 998cm3998cm3998cm3
Bore/Stroke 79.0 × 50.9 mm 79.0 × 50.9 mm 79.0 × 50.9 mm
Maximum engine speed
(limiter controlled speed)
14500 rpm 14500 rpm 14500 rpm
Compression ratio
(recommended value)
13.0 – 13.4
Depending on
head surface
grinding
13.0 13.0
Valve timing (event angle) INT 105° 108° 108°
EXT 108° 110° 110°
Clearance between valve
and piston (minimum)
INT 0.95 mm – –
EXT 1.90 mm – –
Valve (tappet) clearance INT 0.09 – 0.17 mm 0.09 – 0.17 mm 0.09 – 0.17 mm
EXT 0.18 – 0.23 mm 0.18 – 0.23 mm 0.18 – 0.23 mm

– 2 –
2 KitParts
2-1InstallingElectricalParts
1. ECU Set (2CR-8591A-71)
Parts List
No. PART No. PART NAME Q'TY REMARKS
1 2CR-8591A-71 ECU 1
2 2CR-2818Y-71 CD 1 YMS SOFT & MANUAL
'16 Ver.
•Use of this set and a wire harness
included in the kit enables regulation (or
setting) of fuel injection and ignition timing,
etc.
•For details as to how to regulate (or set)
fuel injection and ignition timings, etc.,
refer to the FI matching system manual in
the CD-ROM that comes with the set.
•There are two types of basic control data
for the ECU included in this set: SB (Super
Bike) and ST (Stock Sports). They can be
switched over and vice versa. To make it
in the ST specification, just remove two
couplers located at the lower left of the kit
harness fuel tank.
(Seethegurebelow.)
<Setting-up Details>
SB specification: Kit cam shaft, Kit valve
spring, Kit air funnel set,
*Recommendedmufer
STspecication:*Recommendedmufer
*Recommendedmufer
Made by Akrapovic (For details of the
specication,pleaseaccessthewebsite.)
Web http://www.akrapovic-exhaust.com/
NOTICE
Before using the KIT ECU for the first
time, use YMS to perform writing of the
base map.

– 3 –
The set of the camshaft, valve spring, ECU
and air funnel must be used in the following
combination.
NOTICE
Using in other combinations may possibly
damage the engine.
Be
sure to use in the combination as
stated above.
MODEL CAMSHAFT (IN) CAMSHAFT (EX) VALVE SPRING ECU AIR FUNNEL SET
2015 2CR-12170-70 2CR-12180-70 2CR-A2110-70 2CR-8591A-70 MGC-191114-00
2016 2CR-8591A-71 2CR-1440B-70

– 4 –
2. CableInterface(2CR-8533A-70)
Parts List
No. PART No. PART NAME Q'TY REMARKS
1 2CR-8533A-70 CABLE, INTERFACE 1 USB
2 2CR-N81CD-70 CD 1 USB driver
Windows 8 supported
•This cable connects the kit wire harness
to the personal computer on which YEC FI
Matching System (YMS) is installed.
•Please see the YMS manual for instructions
on how to use YMS.
•When connecting the cable to the PC
for the first time, it is necessary to install
the USB driver. Refer to the USB Driver
Installation Manual provided on the CD for
details on how to install the USB driver.
Diagnosis Functions
•Use of the ECU in the kit and the harness
allows functioning of the following codes in
the STD diagnosis.
CODE Contents
01 Throttle position sensor signal 1
02 Atmospheric pressure
03 Intake air pressure
05 Air temperature
06 Coolant temperature
07 Rear vehicle speed pulse
09 Fuel system voltage
(battery voltage)
13 Throttle position sensor signal 2
14 Accelerator position sensor signal 1
15 Accelerator position sensor signal 2
16 Front vehicle speed pulse
17 Bank angle
20 Pit road limiter
21 YMS MAP SW.
30 Ignition coil #1
31 Ignition coil #2
32 Ignition coil #3
33 Ignition coil #4
34 Intake funnel
36 Injector (primary) #1
CODE Contents
37 Injector (primary) #2
38 Injector (primary) #3
39 Injector (primary) #4
40 Injector (secondary) #1
41 Injector (secondary) #2
42 Injector (secondary) #3
43 Injector (secondary) #4
47 Steering damper solenoid
48 AIS
49 Intake solenoid
50 Main relay
51 Radiator fan
52 Headlight
60 EEPROM
61 Contentconrmation
62 Contentconrmation
63 Contentconrmation
67 ISU
70 Program number
86 Shift switch

– 5 –
Self-Diagnosis Functions
The ECU is equipped with a self-diagnostic
function in order to ensure that the fuel
injection system is operating normally. If this
function detects a malfunction in the system,
it immediately operates the engine under
substitute characteristics and illuminates the
engine trouble warning light to alert the rider
that a malfunction has occurred in the system.
Once a malfunction has been detected, a fault
code is stored in the memory of the ECU.
(* For information about the deletion method,
see 2CR STD Service Manual.)
•To inform the rider that the fuel injection
system is not functioning, the engine
trouble warning light flashes when the
start switch is being pushed to start the
engine.
•If the self-diagnosis function detects
a malfunction in the system, the ECU
performs an appropriate substitute
operation and illuminates the engine
trouble warning light (diagram “1”), and
the fault code number (diagram “2”) is
displayed.
CODE Description
8 Gear position sensor malfunctions
11 Cam angle sensor malfunctions
12 Cylinder angle sensor malfunctions
13 Intake pressure sensor malfunctions
(open circuit / short circuit)
•The ECU and harness in the kit provide
the functions for the following codes of
standard self-diagnosis:
ODO 0
km
FUEL CON --.-
L 1
N
2
km/h
×1000 r/min
MODE-APWR 4TCS 2SCS 2
90 17
12:00
2
1
CODE Description
14 Intake pressure sensor malfunctions
(piping system)
15 Throttle opening sensor malfunctions
(open circuit / short circuit / ETV)
20
Intake pressure sensor or atmospheric
pressure sensor malfunctions
21
Water temperature sensor malfunctions
(open circuit / short circuit)
22
Intake temperature sensor malfunctions
(open circuit / short circuit)
23
Atmospheric pressure sensor
malfunctions (open circuit / short circuit)
33 Ignition coil #1 malfunctions (open circuit)
34 Ignition coil #2 malfunctions (open circuit)
35 Ignition coil #3 malfunctions (open circuit)
36 Ignition coil #4 malfunctions (open circuit)
39 Injector (primary) malfunctions (open
circuit)
40 Injector (secondary) malfunctions
(open circuit)
42 Rear wheel sensor
malfunctions
43 Battery voltage monitor malfunctions
(power source for fuel system)
44 EEPROM malfunctions
45
ECU malfunctions (electrical power
system)
46 Power source for vehicle malfunctions
50 ECU malfunctions (main unit)
59
Accelerator opening sensor malfunctions
(open circuit / short circuit)
60 Throttle motor malfunctions (drive
system)
69 Front wheel sensor malfunctions
70 Engine stop by idling away
98 IMU malfunctions (main unit)
99 IMU malfunctions (communication
system)

– 6 –
3. WireHarnessSet(2CR-F2590-70)
Parts List
No. PART No. PART NAME Q'TY REMARKS
1 2CR-82590-70 WIRE HARNESS ASSY. 1 MAIN HARNESS
° 2 2CR-82386-70 WIRE, SUB-LEAD 1 TH INJECTOR
° 3 2CR-82318-70 WIRE, SUB-LEAD 1 AC INJECTOR
° 4 2CR-82309-70 WIRE, SUB-LEAD 1 IGNITION COIL
° 5 2CR-8231Y-70 WIRE, LEAD 1 FUEL PUMP
° 6 2CR-83553-70 WIRE, LEAD 1 METER
72CR-2128A-70 BRKT., REGULATOR 1 1
* 8 90480-13003 GROMMET 2
*9 90560-06201 SPACER 2
* 10 90111-06051 BOLT, HEX. SOCKET BUTTON 2
*11 95607-06200 NUT, U FLANGE 2
12 2CR-2161E-70 BRKT.,4 1
* 13 90338-06018 PLUG 3
* 14 120-82131-00 BAND, BATTERY 1
* 15 90111-06051 BOLT, HEX. SOCKET BUTTON 1
16 2CR-2161G-70 BRKT.,6 1
* 17 14B-8183G-01 CORD COMP. 1
This wire harness is weight-saved by doing
away with connecting wires for lights.
NOTICE
•Do not remove the AC generator but
leave it to function. Use on the battery
alone will make the machine unable to
run in a short time.
•This wire harness only works when
used in combination with the ECU
(2CR-8591A-70, 71) of the kit.
•Using the KIT ECU disables the ABS
function of the brake, but do not
remove the Hydraulic unit assy. and
connect it to the wire harness of the
kit.
Without this connection, any
computerized controls will not work.
TIP
If the E-SD (STD steering damper) is not
used, removing its coupler will pose no
problem.
No. PART No. PART NAME Q'TY REMARKS
20 2KS-82509-70 WIRE, SUB-LEAD 1 SCU
WIRE, SUB-LEAD
Parts List
This wire harness is for mounting the KIT
harness to a vehicle with the Electric racing
suspension (ERS) function.
NOTICE
• BeforeusingtheKITECUfortherst
time, use YMS to perform writing of
the base map.
•Remove the coupler of the main switch
before starting assembling work.

– 7 –
Installing Wire Harness:
1. Remove the STD wire harness from the
chassis.
2. Cut the shaded area off the battery box (to
provide an installation area for fixing for
BRKT.,4
12
seat).
13
14
11
7
3
20
R6
3. Install PLUG
13
to BRKT.,4
12
.
By using the STD battery box installation
bolt and bolt
15
, install BRKT.,4
12
to the
shaped battery box.
Pass band
14
through BRKT.,6
16
.
Secure the ECU with band
14
.
Install the relay ASSY. and main fuse to
and BRKT.,6
16
.
16 14 15
12
13

– 8 –
4. Cut the shaded area off the LH side cover
(to provide an installation area for sixing
for BRKT., REGULATOR 1 7seat).
102
44 22
R20
49
R20
5. Remove from the chassis the STD
rectifier/regulator that is installed on the
right side of the radiator.
Install the rectifier/regulator using the
bracket, regulator
7, grommets
8,
spacers
9, bolts
10
and nuts
11
.
Face the bracket and regulator 7inward
and tighten them together with the shaped
side cover.
10
11
97
8
6. Replace the STD CORD COMP. (starter
motor lead wire) with the CORD COMP.
17
.

– 9 –
7. Install the wire harness of the kit as the
diagram.
PC I/F
2KS STD RCU
FUSE BOX1
RR.WHEEL SENSOR
ABS ECU
IMU
ECU1/2
ST RELAY1
RELAY ASSY.
POWER SUPPLY
ACM
OIL SW
SHIFT SW
SELECT SW
CRANK SHAFT SENSOR
VI MOTOR
HANDLE SW LH&RH
E-SD SOLENOID
METER SUB LEAD
FR.WHEEL SENSOR
APS
THROTTLE MOTOR
PRESSURE SENSOR(Pa)
PRESSURE SENSOR(Pb)
2KS STD SUB LEAD
MAIN SW
METER
AIR TEMP SENSOR
62CR-83553-70
WIRE, LEAD
2CR-2128A-70
BRKT., REGULATOR 1
2KS-82509-70
WIRE, SUB-LEAD
20
7
, indicate the names of parts to be connected.
POWER SUPPLY 2
2KS SUB LEAD
TPS
REC/REGU

– 10 –
MAIN SW
AIR TEMP SENSOR
METER
CRANK SHAFT SENSOR
METER SUB LEAD
REC/REGU
TPS
SELECT SW
SHIFT SW
OIL SW
FR.WHEEL SENSOR
APS
THROTTLE MOTOR
PRESSURE SENSOR(Pa)
PRESSURE SENSOR(Pb)
VI MOTOR
HANDLE SW LH
HANDLE SW RH
POWER SUPPLY 2
2KS SUB LEAD
MAIN SW
E-SD SOLENOID
ACM
FUSE BOX1
RR.WHEEL SENSOR
ABS ECU
IMU
ECU1/2
ST RELAY1
RELAY ASSY.
POWER SUPPLY
INJECTOR #12/22/32/42
WATER TEMP SENSOR
FUEL PUMP
NEUTRAL SW
EG EARTH
PC I/F
INJECTOR #11/21/31/41
IG.COIL 1/2/3/4
CAM SENSOR
2CR-82386-70
WIRE, SUB-LEAD
2CR-82309-70
WIRE, SUB-LEAD
4
2CR-82386-70
WIRE, SUB-LEAD
2CR-82386-70
WIRE, SUB-LEAD
2
2CR-82386-70
WIRE, SUB-LEAD
2CR-82318-70
WIRE, SUB-LEAD
3
, indicate the names of parts to be connected.

– 11 –
PRESSURE SENSOR(Pa)
PRESSURE SENSOR(Pb)
VI MOTOR
FR.WHEEL SENSOR
THROTTLE MOTOR
APS
, indicate the names of parts to be connected.

– 12 –
ECU2
2KS-2161E-70
BRKT.,4
12
MAIN FUSE
ECU1
POWER SUPPLY
ST RELAY
RELAY ASSY.
ABS ECU
FUSE BOX1
IMU
RR.WHEEL SENSOR
, indicate the names of parts to be connected.

– 13 –
The name and function of each switch
<Left>
<Right>
LAP switch
Keep the switch at low position
Hi position→the LAP switch becomes non-functional
Pit road limiter
ON ON
PUSH=OFF
Not used
Mode switch Up button
Center button
Down button
MAP SELECT
→MAP 1
→MAP 2
Starter switch/Engine stop switch
Wheel switch

– 14 –
YRC : Yamaha Ride Control
Yamaha
Ride Control is a system that
controls the engine output based on data
received from the sensors and IMU.
The functions listed below represent
individual YRC items which can be turned
on/off or adjusted to suit various riders and
riding conditions.
For details on the settings, see “MENU” in
the Owner’s Manual.
* The
meter MENU screen cannot be
displayed if “T.TRIP” is selected when the
battery or meter is reconnected.
IMU : Inertial Measurement Unit
PWR : Power Delivery Mode
TCS : Spin control system
SCS : Slide control system
LCS : Launch control system
QSS : Quick shift system
LIF : Lift control system
ERS : Electric racing suspension by ÖHLINS
(available only with 2KS)
IMU : Inertial Measurement Unit
IMU is 6-axis inertial measurement unit.
It consists of three gyro sensors (angular
sensors) that measure a: machine pitch,
b: roll, and c: yaw, and three G-sensors
(accelerometer) that measure acceleration in
the forward-backward, up-down and right-left
directions. YRC controls the engine output
based on data received from those sensors.
PWR : Power Delivery Mode
The power mode selection system consists of
four different control maps to regulate throttle
valve opening depending on the degree of
throttle opening, thus providing the rider with
aselectionofmodestotrider’spreferences
and the riding environment.
TIP
If the installation position or angle of the
inertial measurement unit is changed,
YRC does not function properly because
measurements are not available.
a
b
c
Throttle grip opening
Throttle
valve
opening
100%
100%0
PWR1
PWR2
PWR3
PWR4
TCS : Spin control system
The spin control system helps maintain
traction when accelerating. If sensors detect
that the rear wheel is
starting to slip (uncontrolled spinning), the
spin control system assists by regulating
engine power as needed until traction is
restored.
This system supports the SCS to contribute
to a smoother ride.
The TCS-1 effect becomes 0.
If TCS is set to “OFF”, SCS, LCS, QSS and
LIF are also set to OFF automatically.
1
5
4
3
2
6
9
8
7
Strong
Weak
Slow Fast
Control ratio
Vehicle speed

– 15 –
SCS : Slide control system
The slide control system controls engine
power output when a sideward slide is
detected in the rear wheel.
It adjusts output to an optimum level based
on data from the IMU, thus helping the rider
focus on riding without distraction.
This system supports the TCS to contribute
to a smoother ride.
1
3
2
Strong
Weak
Slow Fast
Control ratio
Side slide speed
LCS : Launch control system
The launch control system helps ensure
smooth and swift starts.
The LCS maintains an optimum level of
engine output in conjunction with input from
the TCS and LIF systems even with the
throttle fully open.
This allows the rider to concentrate on clutch
engagement and vehicle control to reduce
stress during starts.
LCS works in conjunction with TCS and LIF
systems.
If TCS is set to “OFF”, LIF is also set to OFF
automatically.
QSS : Quick shift system
The quick shift system provides speedy, full-
throttle upshifts.
LIF : Lift control system
The lift control system reducing wheel lift rate
during extreme acceleration, such as during
starts or out-of-corner acceleration.
When front-wheel lift is detected by the IMU,
engine output is adjusted to the optimum
level to compensate for it and thus assist the
rider’s vehicle control.
1
3
2
Strong
Weak
Slow Fast
Control ratio
Front-wheel lift speed
ERS : Electronic racing suspension
The Ohlins electronic racing suspension takes
data from the IMU and the suspension control
unit (SCU) makes integrated adjustments of
both the front and rear suspension’s damping
force based on running conditions.

– 16 –
About the front and rear wheel speed sensor
Do not remove the speed sensors installed at
the front and rear wheels because they are
used for regulating YRC controls.
•If you change the front and rear wheels
to non-standard parts, manufacture and
attach a rotor and sensor referring to the
diagram below.
•If you change the front fork/rear brake
bracket to a non-standard part too, create
a mount for the sensor assembly and
attach the front and rear wheel sensors
referring to the diagram below.
*1. When manufacturing a rotor and sensor,
use a steel type material with magnetic
properties.
*2. Make the angle of attachment in the
rotation direction of the rotor of the sensor
assembly the same as the angle indicated
in the diagram below.
*3. If you change the rotor sensor or sensor
assembly attachment bracket to a non-
standard part, there is a possibility of
malfunction due to vibration or noise even
if the part is attached properly.
THIRD ANGLE PROJECTION METHOD
Sensor mount
Reference shape
M6×1.0
14±0.1
Φ11.8 +0.1
0
ROTOR, SENSOR
0.8 – 2.3
ROTOR, SENSOR
t2
2CR-85970-00
Center of sensor
D/2±0.2
Rotation direction
100°
FR. WHEEL SENSOR ASSY.
2CR-85980-00
RR. WHEEL SENSOR ASSY.
(40 parts
equiangularly)
Diameter at sensor
detecting position
ΦD (90 – 180)
40×4±0.05
(when D=Φ90: 4 mm, when D=Φ180: 8 mm)
Holes (40 locations)
40×8±0.2
(4)

– 17 –
4. HeadlightHarnessSet(2CR-F4350-70)
Parts List
No. PART No. PART NAME Q'TY REMARKS
1 2CR-84359-70 CORD, HEAD LIGHT 1
* 2 1ST-81950-00 RELAY ASSY. 2
* 3 5GF-83976-00 SW., HANDLE 1 2 Light ON/OFF SW.
Emergency SW.
This set is used in endurance races in
combination with the kit harness for turning on
the STD headlights and taillights.
It assumes that the standard headlights and
taillights are used.
When using STD headlights, you can use the
coupler of either HEAD LIGHT 1 or HEAD
LIGHT 2. (Diagram 1.)
The headlight lights up on both the Hi and
Low sides.
The headlight and taillight circuits are
independent of one another. If the headlight is
broken, the taillight will not go out.
The blue coupler works as the Light ON/
OFF SW. to turn on the headlight and taillight.
(Diagram 1.)
The red coupler works as the Emergency SW.
to turn on the taillight only. (Diagram 1.)
(Diagram 1.)