Yamaha YZF-R1V Manual

YZF-R1V
5VY-28197-11
SUPPLEMENTARY
SERVICE MANUAL
LIT-11616-19-75
YZF-R1VC
YZF-R1LEV
YZF-R1LEVC

YZF-R1V/YZF-R1VC
YZF-R1LEV/YZF-R1LEVC
SUPPLEMENTARY
SERVICE MANUAL
©2005 by Yamaha Motor
Corporation, U.S.A.
First edition, October 2005
All rights reserved. Any reproduction
or unauthorized use without the written
permission of Yamaha Motor Corporation,
U.S.A. is expressly prohibited.
Printed in U.S.A.
LIT-11616-19-75
EAS00001
FOREWORD
This Supplementary Service Manual has been prepared to introduce new service and data for the
YZF-R1V/YZF-R1VC/YZF-R1LEV/YZF-R1LEVC. For complete service information procedures it is
necessary to use this Supplementary Service Manual together with the following manual.
YZF-R1S/YZF-R1SC SERVICE MANUAL: LIT-11616-17-55 (5VY-28197-10)

EAS00030
NOTICE
This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha deal-
ers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one
manual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha
vehicles should have a basic understanding of mechanics and the techniques to repair these types
of vehicles. Repair and maintenance work attempted by anyone without this knowledge is likely to
render the vehicle unsafe and unfit for use.
This model has been designed and manufactured to perform within certain specifications in regard
to performance and emissions. Proper service with the correct tools is necessary to ensure that the
vehicle will operate as designed. If there is any question about a service procedure, it is imperative
that you contact a Yamaha dealer for any service information changes that apply to this model. This
policy is intended to provide the customer with the most satisfaction from his vehicle and to conform
to federal environmental quality objectives.
Yamaha Motor Company, Ltd. is continually striving to improve all of its models. Modifications and
significant changes in specifications or procedures will be forwarded to all authorized Yamaha deal-
ers and will appear in future editions of this manual where applicable.
N
O
TE:
• This Service Manual contains information regarding periodic maintenance to the emission control
system. Please read this material carefully.
• Designs and specifications are subject to change without notice.
EAS00040
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!
Failure to follow WARNING instructions could result in severe injury or death
to the vehicle operator, a bystander or a person checking or repairing the
vehicle.
A CAUTION indicates special precautions that must be taken to avoid dam-
age to the vehicle.
A NOTE provides key information to make procedures easier or clearer.
WARNING
CAUTION:
NOTE:

EAS00007
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.
The manual is divided into chapters. An abbreviation and symbol in the upper right corner of
each page indicate the current chapter.
Refer to “SYMBOLS”.
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 ADJUSTMENTS”), where the sub-section title(s)
appears.
Sub-section titles appear in smaller print than the section title.
To help identify parts and clarify procedure steps, there are exploded diagrams at the start of
each removal and disassembly section.
Numbers are given in the order of the jobs in the exploded diagram. A circled number indicates a
disassembly step.
Symbols indicate parts to be lubricated or replaced.
Refer to “SYMBOLS”.
A job instruction chart accompanies the exploded diagram, providing the order of jobs, names of
parts, notes in jobs, etc.
Jobs requiring more information (such as special tools and technical data) are described
sequentially.

EAS00008
SYMBOLS
The following symbols are not relevant to every
vehicle.
Symbols to indicate the subject of each
chapter.
General information
Specifications
Periodic checks and adjustments
Chassis
Engine
Cooling system
Fuel injection system
Electrical system
Troubleshooting
Symbols to indicate the following.
Serviceable with engine mounted
Filling fluid
Lubricant
Special tool
Tightening torque
Wear limit, clearance
Engine speed
Electrical data
Symbols to in the exploded diagrams
indicate the types of lubricants and lubrication
points.
Engine oil
Gear oil
Molybdenum-disulfide oil
Wheel-bearing grease
Lithium-soap-based grease
Molybdenum-disulfide grease
Symbols to in the exploded diagrams
indicate the following.
Apply locking agent (LOCTITE®)
Replace the part with a new one.

CONTENTS
GENERAL INFORMATION
SPECIAL TOOLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
SPECIFICATIONS
GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
ENGINE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
CHASSIS SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
ELECTRICAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
ENGINE TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . . . . . . 7
CHASSIS TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . . . . . 8
LUBRICATION POINTS AND LUBRICANT TYPES . . . . . . . . . . . . . . 9
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
LUBRICATION DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
CABLE ROUTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
PERIODIC CHECKS AND ADJUSTMENTS
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
PERIODIC MAINTENANCE CHART FOR THE EMISSION
CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
GENERAL MAINTENANCE AND LUBRICATION CHART . . . . . . . . 27
CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
ADJUSTING THE FRONT FORK LEGS. . . . . . . . . . . . . . . . . . . . . 29
ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY . . . . . 32
CHASSIS
FRONT WHEEL AND BRAKE DISCS . . . . . . . . . . . . . . . . . . . . . . . . . 35
REAR WHEEL AND BRAKE DISCS . . . . . . . . . . . . . . . . . . . . . . . . . . 36
REAR BRAKE DISC AND REAR WHEEL SPROCKET . . . . . . . . . 36
FRONT FORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
FRONT FORK LEGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
DISASSEMBLING THE FRONT FORK LEGS . . . . . . . . . . . . . . . . 40
CHECKING THE FRONT FORK LEGS . . . . . . . . . . . . . . . . . . . . . 42
ASSEMBLING THE FRONT FORK LEGS . . . . . . . . . . . . . . . . . . . 43
REAR SHOCK ABSORBER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 47
REMOVING THE REAR SHOCK ABSORBER ASSEMBLY . . . . . 49
INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY . . . . . 50
SWINGARM AND DRIVE CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
REMOVING THE SWINGARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
CHECKING THE SWINGARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
CHECKING THE CONNECTING ROD ASSEMBLY . . . . . . . . . . . 53
CHECKING THE DRIVE CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

ENGINE
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
INSTALLING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
CAMSHAFTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
CLUTCH COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
REMOVING THE CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
CHECKING THE FRICTION PLATES . . . . . . . . . . . . . . . . . . . . . . 67
CHECKING THE CLUTCH PLATES. . . . . . . . . . . . . . . . . . . . . . . . 68
CHECKING THE CLUTCH SPRINGS . . . . . . . . . . . . . . . . . . . . . . 69
CHECKING THE CLUTCH HOUSING . . . . . . . . . . . . . . . . . . . . . . 69
CHECKING THE PRESSUR PLATE 2 . . . . . . . . . . . . . . . . . . . . . . 70
CHECKING THE CLUTCH BOSS . . . . . . . . . . . . . . . . . . . . . . . . . 70
CHECKING THE PRESSURE PLATE 1 . . . . . . . . . . . . . . . . . . . . . 70
CHECKING THE PULL LEVER SHAFT AND PULL ROD . . . . . . . 71
INSTALLING THE CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
YZF-R1V/YZF-R1VC/YZF-R1LEV /YZF-R1LEVC 2006 WIRING DIAGRAM

GEN
INFO
1
EAS00027
GENERAL INFORMATION
SPECIAL TOOLS
The following special tools are necessary for complete and accurate tune-up and assembly. Use
only the appropriate special tools as this will help prevent damage caused by the use of inappropri-
ate tools or improvised techniques. Special tools, part numbers or both may differ depending on the
country.
When placing an order, refer to the list provided below to avoid any mistakes.
N
O
TE:
• For U.S.A. and Canada, use part number starting with “YM-”, “YU-”, or “ACC-”.
• For others, use part number starting with “90890-”.
(YZF-R1LE)
Tool No. Tool name/Function Illustration
90890-01472
Front fork cap bolt wrench
This tool is used to loosen or tighten the front
fork cap bolt.
90890-01504
Damper rod holder
This tool is used to loosening or tightening
the damper rod assembly.
Rod puller
90890-01437
YM-A8703
Rod puller
attachment
90890-01435
YM-A8703
Rod puller
Rod puller attachment
These tools are used to pull up the front fork
damper rod.
SPECIAL TOOLS

SPEC
2
SPECIFICATIONS
GENERAL SPECIFICATIONS
Item Standard Limit
Model code YZF-R1
5VYH (USA), 5VYL (USA) •••
5VYJ (CAL), 5VYM (CAL)
YZF-R1LE
4B14 (USA), 4B15 (CAL) •••
Dimensions
Overall length 2,085 mm (82.1 in) •••
Wheelbase 1,415 mm (55.7 in) •••
Weight
Wet (with oil and a full fuel tank) 194 kg (428 lb) (USA) (YZF-R1) •••
195 kg (430 lb) (CAL) (YZF-R1) •••
195 kg (430 lb) (USA) (YZF-R1LE) •••
195 kg (430 lb) (CAL) (YZF-R1LE) •••
Maximum load (except vehicle) 201 kg (443 lb) (USA) (YZF-R1) •••
200 kg (441 lb) (CAL) (YZF-R1) •••
200 kg (441 lb) (USA) (YZF-R1LE) •••
200 kg (441 lb) (CAL) (YZF-R1LE) •••
GENERAL SPECIFICATIONS

SPEC
3
ENGINE SPECIFICATIONS
Item Standard Limit
Oil pump
Oil-pump-housing-to-inner-and-outer-
rotor clearance
0.06 ~ 0.13 mm
(0.0024 ~ 0.0051 in)
0.20 mm
(0.0079 in)
Cylinder head
Volume 12.3 ~ 12.9 cm3(0.75 ~ 0.79 cu.in) •••
Max. warpage ••• 0.10 mm
(0.0039 in)
Piston
Diameter D 76.975 ~ 76.990 mm (3.0305 ~ 3.0311 in) •••
Height H 12 mm (0.47 in) •••
Clutch
Friction plates
Color code Red •••
Thickness 2.9 ~ 3.1 mm (0.114 ~ 0.122 in) 2.8 mm
(0.110 in)
Plate quantity 7 •••
Color code Red •••
Thickness 2.9 ~ 3.1 mm (0.114~ 0.122 in) 2.8 mm
(0.110 in)
Plate quantity 1 •••
Color code Red •••
Thickness 2.9 ~ 3.1 mm (0.114 ~ 0.122 in) 2.8 mm
(0.110 in)
Plate quantity 1 •••
Clutch plates
Thickness 1.9 ~ 2.1 mm (0.07 ~ 0.08 in) •••
Plate quantity 8 •••
Max. warpage ••• 0.1 mm
(0.0039 in)
Clutch springs
Free length 43.8 mm (1.72 in) (YZF-R1LE) 41.6 mm
(1.64 in)
Throttle bodies
ID mark 5VY1 30 (USA), 5VY1 40 (CAL) •••
ENGINE SPECIFICATIONS

SPEC
4
CHASSIS SPECIFICATIONS
Item Standard Limit
Front wheel
Wheel type Forged wheel (YZF-R1LE) •••
Rear wheel
Wheel type Forged wheel (YZF-R1LE) •••
Front tire
Model (manufacturer) Pilot POWER (MICHELIN) (YZF-R1) •••
D218FG (DUNLOP) (YZF-R1) •••
DIABLO CORSA H (PIRELLI) (YZF-R1LE) •••
Tire pressure (cold)
90 ~ 201 kg (198 ~ 443 lb) 250 kPa (2.5 kgf/cm2, 2.5 bar, 35.6 psi)
(USA) (YZF-R1)
•••
90 ~ 200 kg (198 ~ 441 lb) 250 kPa (2.5 kgf/cm2, 2.5 bar, 35.6 psi)
(CAL) (YZF-R1)
•••
90 ~ 200 kg (198 ~ 441 lb) 250 kPa (2.5 kgf/cm2, 2.5 bar, 35.6 psi)
(USA) (YZF-R1LE)
•••
90 ~ 200 kg (198 ~ 441 lb) 250 kPa (2.5 kgf/cm2, 2.5 bar, 35.6 psi)
(CAL) (YZF-R1LE)
•••
Rear tire
Model (manufacturer) Pilot POWER/Pilot POWER G
(MICHELIN) (YZF-R1)
•••
D218G (DUNLOP) (YZF-R1) •••
DIABLO CORSA (PIRELLI) (YZF-R1LE) •••
Tire pressure (cold)
90 ~ 201 kg (198 ~ 443 lb) 290 kPa (2.9 kgf/cm2, 2.9 bar, 41.3 psi)
(USA) (YZF-R1)
•••
90 ~ 200 kg (198 ~ 441 lb) 290 kPa (2.9 kgf/cm2, 2.9 bar, 41.3 psi)
(CAL) (YZF-R1)
•••
90 ~ 200 kg (198 ~ 441 lb) 290 kPa (2.9 kgf/cm2, 2.9 bar, 41.3 psi)
(USA) (YZF-R1LE)
•••
90 ~ 200 kg (198 ~ 441 lb) 290 kPa (2.9 kgf/cm2, 2.9 bar, 41.3 psi)
(CAL) (YZF-R1LE)
•••
CHASSIS SPECIFICATIONS

SPEC
5
Item Standard Limit
Front brakes
Master cylinder inside diameter 16 mm (0.63 in) •••
Caliper cylinder inside diameter 30.2 mm and 27 mm (1.19 in and 1.06 in) •••
Front suspension
(YZF-R1)
Fork oil
Quantity (each front fork leg) 0.52 L (0.46 Imp qt, 0.55 US qt) •••
Level (from the top of the outer tube,
with the outer tube fully compressed,
and without the fork spring)
90 mm (3.54 in) •••
Spring preload adjusting positions
Minimum 8 •••
Standard 4.5 •••
Maximum 0 •••
(YZF-R1LE)
Spring
Free length 260 mm (10.24 in) 254.8 mm
(10.03 in)
Coller length 42 mm (1.653 in) •••
Installed length 248.0 mm (9.76 in) •••
Spring rate (K1) 9.50 N/mm (0.97 kg/mm, 54.22 lb/in) •••
Fork oil
Recommended oil Suspension oil “Ohlins R&T 43”
(ACC-RT43F-00-00)
•••
Quantity (each front fork leg) 0.43 L (0.38 Imp qt, 0.45 US qt) •••
Level (from the top of the outer tube,
with the outer tube fully compressed,
and without the fork spring)
145 mm (5.71 in) •••
Spring preload adjusting positions
Minimum* 11 turns out* •••
Maximum* 2 turns in* •••
*from the standard position
Rebound damping adjusting positions
Minimum** 17 •••
Standard** 12 •••
Maximum** 1 •••
Compression damping adjusting
positions
Minimum** 20 •••
Standard** 12 •••
Maximum** 1 •••
**from the fully turned-in direction
CHASSIS SPECIFICATIONS

SPEC
6
Item Standard Limit
Rear suspension
(YZF-R1)
Spring preload adjusting positions
Minimum 1 •••
Standard 5 •••
Maximum 9 •••
(YZF-R1LE)
Spring
Free length 150.0 mm (5.91 in) •••
Installed length 139.0 mm (5.47 in) •••
Spring rate (K1) 95.0 N/mm (9.68 kg/mm, 542.18 lb/in) •••
Spring preload adjusting positions
Minimum* 0 •••
Standard* 6 •••
Maximum* 20 •••
Rebound damping adjusting positions
Minimum* 18 •••
Standard* 14 •••
Maximum* 1 •••
Compression damping adjusting
positions (fast compression damping)
Minimum* 42 •••
Standard* 30 •••
Maximum* 1 •••
Compression damping adjusting
positions (slow compression damping)
Minimum* 17 •••
Standard* 10 •••
Maximum* 1 •••
*from the fully turned-in position
Drive chain
Model (manufacturer) 50VA8 (DAIDO) •••
Link quantity 118 •••
Drive chain slack 20 ~ 25 mm (0.79 ~ 0.98 in) •••
Maximum 15-link section ••• 239.3 mm
(9.42 in)
CHASSIS SPECIFICATIONS

SPEC
7
ELECTRICAL SPECIFICATIONS
TIGHTENING TORQUES
ENGINE TIGHTENING TORQUES
Item Standard Limit
Ignition system
T.C.I. unit model (manufacturer) F8T82075 (MITSUBISHI) •••
Battery
Manufacturer GS-YUASA •••
Ten hour rate amperage 0.9 A •••
Item Fastener Thread
size Q’ty Tightening torque Remarks
Nm m•kg ft•lb
Exhaust pipe and exhaust valve pipe
assembly
Bolt M6 512 1.2 8.7
EXUP servo motor Bolt M6 2 6 0.6 4.3
Crankcase Bolt M6 10 10 1.0 7.2
Drive sprocket cover Bolt M6 212 1.2 8.7
Drive sprocket cover Bolt M6 112 1.2 8.7
Plate Bolt M6 212 1.2 8.7
ELECTRICAL SPECIFICATIONS/TIGHTENING TORQUES

SPEC
8
CHASSIS TIGHTENING TORQUES
Item Thread
size
Tightening Remarks
Nm m•kg ft•lb
Horn bracket and under bracket M6 7 0.7 5.1
Connecting rod assembly (YZF-R1LE) M6 8 0.8 5.8
Side cover and fuel tank M5 4 0.4 2.9
Front fork and stay (YZF-R1LE) M5 6 0.6 4.3
Front fork and bracket (YZF-R1LE) M5 6 0.6 4.3
Rear brake master cylinder and foot rest bracket M6 13 1.3 9.4
Front brake disc and front wheel (YZF-R1LE) M6 23 2.3 17
Front wheel axle pinch bolt (YZF-R1LE) M8 26 2.6 19 See NOTE
Cap bolt (YZF-R1LE) – 20 2.0 14
Cap bolt and lock nut (YZF-R1LE) M12 25 2.5 18
Damper rod assembly (YZF-R1LE) – 48 4.8 35
N
O
TE:N
O
TE:
1. Insert the front wheel axle from the right
side and tighten it with the flange bolt from
the left side to 91 Nm (9.1 m•kg, 65.8 ft•lb).
2. In the order from the pinch bolt →pinch
bolt →pinch bolt , tighten each bolt to
26 Nm (2.6 m•kg, 19 ft•lb) without perform-
ing temporary tightening.
3. Check that the end face of the axle head
and the end face of the fork side are flush-
mounted. If they are out of alignment, make
sure to fit them by adding the external force
by hand or with a plastic hammer, etc.
If the end face of the axle is not parallel to
the end face of the fork, align them so that
one point of the axle circumference is posi-
tioned on the end face of the fork.
At this stage, it can be accepted if the end
face of the axle becomes partially concave
to the end face of the fork.
4. In the order from the pinch bolt →pinch
bolt →pinch bolt , tighten each bolt to
26 Nm (2.6 m•kg, 19 ft•lb) without perform-
ing temporary tightening.
TIGHTENING TORQUES

SPEC
9
EAS00031
LUBRICATION POINTS AND LUBRICANT TYPES
ENGINE
EAS00032
CHASSIS
Lubrication point Lubricant
Valve lifter surfaces (intake and exhaust)
Valve stem ends (intake and exhaust)
Lubrication point Lubricant
Pivot shaft
LUBRICATION POINTS AND LUBRICANT TYPES

SPEC
10
LUBRICATION DIAGRAMS
Main axle
Oil delivery pipe
Drive axle
LUBRICATION DIAGRAMS

SPEC
11
EAS00035
CABLE ROUTING
Ground lead
Meter lead
Stay 1
Auxiliary light lead (right)
Headlight lead
Auxiliary light lead (left)
Console panel 1
Duct 1
Console panel 2
Duct 2
Headlight lead (right)
Headlight lead (left)
Insert to the rib of the head
light. (Either location of the right
and left relays is acceptable.)
The lead should not stretch too
much.
Direction of the ground terminal
can be either top side or flip
side.
Make sure to insert the coupler
and boot to the stay 1 hole.
The speedometer lead should
not be strained.
To the stay 1 hole
Connect after passing over the
upper side of the duct.
Clamp the head light lead by
wrapping and insert it to the
intake air grill hole. (only at the
right side.)
Do not connect the wire to the
coupler with the plug for
options.
To the turn signal light
To the wire harness
Cut the tip of the clamp.
Clamp the headlight lead to the
positioning white tape section.
CABLE ROUTING

SPEC
12
There should be no slack when
clamping. Point the tip of the
clamp (excessive part) to the
front side of the vehicle. Fasten
the head light lead with a clamp.
Feed a lead wire through the U
shape cutout of the console
panel.
CABLE ROUTING