Yamaha YZFR1Y(C) 2009 User manual

SERVICE MANUAL
YZFR1Y(C)
14B-28197-10LIT-11616-22-78
2009

EAS20050
YZFR1Y(C)
SERVICE MANUAL
©2008 by Yamaha Motor Corporation, U.S.A.
First edition, December 2008
All rights reserved.
Any reproduction or unauthorized use without
the written permission of Yamaha Motor Cor-
poration, U.S.A. is expressly prohibited.
Printed in U.S.A.
P/N LIT-11616-22-78

EAS20071
IMPORTANT
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.
TIP
• 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.
EAS20081
IMPORTANT MANUAL INFORMATION
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 per-
sonal 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.
WARNING

EAS20090
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 and each chapter is divided into sections. The current section
title “1” is shown at the top of each page.
• Sub-section titles “2” appear in smaller print than the section title.
• To help identify parts and clarify procedure steps, there are exploded diagrams “3” at the start of
each removal and disassembly section.
• Numbers “4” are given in the order of the jobs in the exploded diagram. A number indicates a dis-
assembly step.
• Symbols “5” indicate parts to be lubricated or replaced.
Refer to “SYMBOLS”.
• A job instruction chart “6” accompanies the exploded diagram, providing the order of jobs, names
of parts, notes in jobs, etc.
• Jobs “7” requiring more information (such as special tools and technical data) are described
sequentially.

EAS20100
SYMBOLS
The following symbols are used in this manual for easier understanding.
TIP
The following symbols are not relevant to every vehicle.
SYMBOL DEFINITION SYMBOL DEFINITION
Serviceable with engine
mounted Gear oil
Filling fluid Molybdenum disulfide oil
Lubricant Brake fluid
Special tool Wheel bearing grease
Tightening torque Lithium-soap-based grease
Wear limit, clearance Molybdenum disulfide grease
Engine speed Silicone grease
Electrical data Apply locking agent (LOC-
TITE®).
Engine oil Replace the part with a new
one.

1
2
3
4
5
6
7
8
9
EAS20110 TABLE OF CONTENTS
GENERAL INFORMATION
SPECIFICATIONS
PERIODIC CHECKS AND ADJUSTMENTS
CHASSIS
ENGINE
COOLING SYSTEM
FUEL SYSTEM
ELECTRICAL SYSTEM
TROUBLESHOOTING

1
GENERAL INFORMATION
IDENTIFICATION..........................................................................................1-1
VEHICLE IDENTIFICATION NUMBER...................................................1-1
MODEL LABEL.......................................................................................1-1
FEATURES ...................................................................................................1-2
OUTLINE OF THE FI SYSTEM..............................................................1-2
FI SYSTEM.............................................................................................1-3
YCC-T (Yamaha Chip Controlled Throttle)
YCC-I (Yamaha Chip Controlled Intake) .................................................1-4
INSTRUMENT FUNCTIONS ..................................................................1-8
IMPORTANT INFORMATION .....................................................................1-15
PREPARATION FOR REMOVAL AND DISASSEMBLY........................1-15
REPLACEMENT PARTS.......................................................................1-15
GASKETS, OIL SEALS AND O-RINGS................................................1-15
LOCK WASHERS/PLATES AND COTTER PINS.................................1-15
BEARINGS AND OIL SEALS ...............................................................1-16
CIRCLIPS .............................................................................................1-16
CHECKING THE CONNECTIONS .............................................................1-17
HANDLING THE ELECTRONIC PARTS....................................................1-18
SPECIAL TOOLS........................................................................................1-19

IDENTIFICATION
1-1
EAS20130
IDENTIFICATION
EAS20140
VEHICLE IDENTIFICATION NUMBER
The vehicle identification number “1” is
stamped into the right side of the steering
head pipe.
EAS20150
MODEL LABEL
The model label “1” is affixed to the seat rail
reinforcement under the passenger seat. This
information will be needed to order spare
parts.

FEATURES
1-2
EAS20170
FEATURES
EAS30340
OUTLINE OF THE FI SYSTEM
The main function of a fuel supply system is to provide fuel to the combustion chamber at the opti-
mum air-fuel ratio in accordance with the engine operating conditions and the atmospheric tempera-
ture. In the conventional carburetor system, the air-fuel ratio of the mixture that is supplied to the
combustion chamber is created by the volume of the intake air and the fuel that is metered by the jet
used in the respective carburetor.
Despite the same volume of intake air, the fuel volume requirement varies by the engine operating
conditions, such as acceleration, deceleration, or operating under a heavy load. Carburetors that
meter the fuel through the use of jets have been provided with various auxiliary devices, so that an
optimum air-fuel ratio can be achieved to accommodate the constant changes in the operating con-
ditions of the engine.
As the requirements for the engine to deliver more performance and cleaner exhaust gases
increase, it becomes necessary to control the air-fuel ratio in a more precise and finely tuned man-
ner. To accommodate this need, this model has adopted an electronically controlled fuel injection
(FI) system, in place of the conventional carburetor system. This system can achieve an optimum
air-fuel ratio required by the engine at all times by using a microprocessor that regulates the fuel
injection volume according to the engine operating conditions detected by various sensors.
The adoption of the FI system has resulted in a highly precise fuel supply, improved engine
response, better fuel economy, and reduced exhaust emissions.
1. Intake air temperature sensor
2. Engine trouble warning light
3. Air induction system solenoid
4. Atmospheric pressure sensor
5. Intake air pressure sensor
6. Intake funnel servo motor
7. Secondary injectors
8. Throttle servo motor
9. Throttle position sensor
10.Accelerator position sensor
11.Primary injectors
12.Fuel pump
13.Lean angle sensor
14.Relay unit (fuel pump relay)
15.O2sensor
16.Speed sensor
17.Coolant temperature sensor
18.Crankshaft position sensor
19.Spark plugs
20.Ignition coils
21.Cylinder identification sensor
22.ECU (engine control unit)

FEATURES
1-3
EAS14B1017
FI SYSTEM
The fuel pump delivers fuel to the fuel injector via the fuel filter. The pressure regulator maintains the
fuel pressure that is applied to the fuel injector at only 324 kPa (3.24 kgf/cm², 47.0 psi). Accordingly,
when the energizing signal from the ECU energizes the fuel injector, the fuel passage opens, caus-
ing the fuel to be injected into the intake manifold only during the time the passage remains open.
Therefore, the longer the length of time the fuel injector is energized (injection duration), the greater
the volume of fuel that is supplied. Conversely, the shorter the length of time the fuel injector is ener-
gized (injection duration), the lesser the volume of fuel that is supplied.
The injection duration and the injection timing are controlled by the ECU. Signals that are input from
the throttle position sensor, accelerator position sensor, coolant temperature sensor, atmospheric
pressure sensor, cylinder identification sensor, lean angle sensor, crankshaft position sensor, intake
air pressure sensor, air temperature sensor, speed sensor and O2sensor enable the ECU to deter-
mine the injection duration. The injection timing is determined through the signals from the crank-
shaft position sensor. As a result, the volume of fuel that is required by the engine can be supplied at
all times in accordance with the driving conditions.
1. Secondary injector
2. Fuel pump
3. Primary injector
4. Cylinder identification sensor
5. ECU (engine control unit)
6. Throttle position sensor
7. Accelerator position sensor
8. Speed sensor
9. Intake air temperature sensor
10.Lean angle sensor
11.O2sensor
12.Catalytic converter
13.Coolant temperature sensor
14.Crankshaft position sensor
15.Intake air pressure sensor
16.Throttle servo motor
17.Throttle body
18.Atmospheric pressure sensor
19.Air filter case
20.Intake funnel servo motor
A. Fuel system
B. Air system
C. Control system

FEATURES
1-4
EAS14B1076
YCC-T (Yamaha Chip Controlled Throttle) YCC-I (Yamaha Chip Controlled Intake)
Mechanism characteristics
Yamaha developed the YCC-T and YCC-I system employing the most advanced electronic control
technologies. Electronic control throttle systems have been used on automobiles, but Yamaha has
developed a faster, more compact system specifically for the needs of a sports motorcycle. The
Yamaha-developed system has a high-speed calculating capacity that produces computations of
running conditions every 1/1000th of a second.
The YCC-T system is designed to respond to the throttle action of the rider by having the ECU
instantaneously calculate the ideal throttle valve opening and generate signals to operate the motor-
driven throttle valves and thus actively control the intake air volume.
The ECU contains three CPUs with a capacity about five times that of conventional units, making it
possible for the system to respond extremely quickly to the slightest adjustments made by the rider.
In particular, optimized control of the throttle valve opening provides the optimum volume of intake
air for easy-to-use torque, even in a high-revving engine.
The YCC-I system calculates the value from the engine revolution number and throttle opening rate,
activates the intake air funnel with the electronic control motor drive to control the intake pipe length
in order to gain the high power output in all revolution ranges from low speeds to high speeds.
Aims and advantages of using YCC-T system
• Increased engine power
By shortening the air intake path, higher engine speed is possible →Increased engine power.
• Improved driveability
Air intake volume is controlled according to the operating conditions →Improved throttle response
to meet engine requirement.
Driving force is controlled at the optimal level according to the transmission gear position and
engine speed →Improved throttle control.
• Engine braking control
Due to the throttle control, optimal engine braking is made possible.
• Simplified idle speed control (ISC) mechanism
The bypass mechanism and ISC actuator are eliminated →A simple mechanism is used to main-
tain a steady idle speed.
• Reduced weight
Compared to using a sub-throttle mechanism, weight is reduced.
1. Throttle servo motor
2. Accelerator position sensor
3. Throttle cable pulley with linkage guard
4. Throttle valves
5. Throttle position sensor
A. To throttle grip

FEATURES
1-5
Aims and advantages of using YCC-I system
• Improvement of the engine power characteristics
The high power design in all ranges is now provided by having both two features of the short
intake function to ensure the power at the high speed revolution of engine, and the long intake
function to ensure the power in the practical use range.
• Intake pipe length switching control using the motor
The intake pipe length switching operation in a minute time is now available by means of the motor
drive using the electronic control. The smooth power characteristic is provided, which does not let
an operator feel the switching action by the optimization of its switching revolution number and the
most suitable application of engine at the time of changing the revolution.
A. Down position (long intake)
(Low rpm to Mid rpm)
B. Up position (short intake)
(High rpm)

FEATURES
1-6
YCC-T/YCC-I system outline
1. Throttle position sensor
2. Throttle servo motor
3. Accelerator position sensor
4. ECU (engine control unit)
5. ETV main CPU (32 bit)
6. FI CPU (32 bit)
7. Throttle servo motor driver
8. Throttle servo motor driver operation sens-
ing/shut off circuit
9. Throttle servo motor driver operation sens-
ing feedback/emergency stop
10.Emergency stop
11.Engine revolution (pulse signal)
12.Sensor input
13.Neutral switch
14.Crankshaft position sensor
15.Speed sensor
16.Coolant temperature sensor
17.Atmospheric pressure sensor
18.Intake funnel servo motor driver
19.Intake funnel servo motor

FEATURES
1-7
YCC-T/YCC-I control outline
1. Accelerator position sensor
2. Throttle position sensor
3. Crankshaft position sensor
4. Speed sensor
5. D-mode switch
6. Coolant temperature sensor
7. Neutral switch
8. Atmospheric pressure sensor
9. Accelerator position (two signals)
10.Throttle position (two signals)
11.Engine revolution
12.Vehicle speed
13.Coolant temperature
14.Neutral/In gear
15.Atmospheric pressure
16.Throttle servo motor
17.ECU (engine control unit)
18.Base map
19.Idle speed control
20.Calculated throttle valve opening angle
21.Base map
22.Air funnel position (Calculation value)
23.Intake funnel servo motor

FEATURES
1-8
EAS14B4002
INSTRUMENT FUNCTIONS
Multi-function meter unit
WARNING
EWA14B1014
Be sure to stop the vehicle before making
any setting changes to the multi-function
meter unit. Changing settings while riding
can distract the operator and increase the
risk of an accident.
The multi-function meter unit is equipped with
the following:
• A speedometer
• A tachometer
• An odometer
• Two tripmeters (which show the distance
traveled since they were last set to zero)
• A fuel reserve tripmeter (which shows the
distance traveled since the fuel level warning
light came on)
• A stopwatch
•Aclock
• A coolant temperature display
• An air intake temperature display
• A transmission gear display
• A drive mode display (which shows the
selected drive mode)
• A throttle opening position display
• A fuel consumption display (instantaneous
and average consumption functions)
• A self-diagnosis device
• A display brightness, shift timing indicator
light and throttle opening position display
control mode
TIP
• Be sure to turn the key to “ON” before using
the “SELECT” and “RESET” buttons.
• To switch the speedometer and odometer/
tripmeter/fuel consumption displays between
kilometers and miles, press the “SELECT”
button for at least one second.
Tachometer
The electric tachometer allows the rider to
monitor the engine speed and keep it within
the ideal power range.
When the key is turned to “ON”, the tachome-
ter needle sweeps once across the r/min range
and then returns to zero r/min in order to test
the electrical circuit.
ECA14B1015
Do not operate the engine in the tachome-
ter red zone.
Red zone: 13750 r/min and above
1. “RESET” button
2. “SELECT” button
3. Tachometer
4. Shift timing indicator light
5. Throttle opening position display
6. Coolant temperature display/air intake tem-
perature display
7. Drive mode display
8. Speedometer
9. Odometer/tripmeter/fuel reserve tripmeter/
instantaneous fuel consumption/average
fuel consumption
10.Clock/stopwatch
11.Transmission gear display 1. Tachometer
2. Tachometer red zone

FEATURES
1-9
Clock and stopwatch modes
To set the clock
1. Push the “SELECT” button and “RESET”
button together for at least two seconds.
2. When the hour digits start flashing, push
the “RESET” button to set the hours.
3. Push the “SELECT” button, and the minute
digits start flashing.
4. Push the “RESET” button to set the min-
utes.
5. Push the “SELECT” button and then
release it to start the clock.
To display the stopwatch
To change the display to the stopwatch mode,
push the “SELECT” button and “RESET” but-
ton together. To change the display back to the
clock mode at any time, except when the stop-
watch is counting, push the “SELECT” button
and “RESET” button together.
Standard measurement
1. Push the “RESET” button to start the stop-
watch.
2. Push the “SELECT” button to stop the stop-
watch.
3. Push the “SELECT” button again to reset
the stopwatch.
Split-time measurement
1. Push the “RESET” button to start the stop-
watch.
2. Push the “RESET” button or start switch
“ ” to measure split-times. Split-times are
displayed on the odometer display for five
seconds.
3. Push the “RESET” button or start switch
“ ” to display the final split-time or push
the “SELECT” button to stop the stopwatch
and display the total elapsed time.
Split-time history
The split-time history displays up to 20 stored
split times. The split-time history can be dis-
played either in reverse chronological order or
by speed.
1. Push the “SELECT” button for at least one
second to select the reverse chronological
order mode; “L20” displays on the stop-
watch.
Push the “SELECT” button again to select
the speed mode; “F20” displays on the
stopwatch.
2. Push the “RESET” button. Depending on
the selected split time, “L20” or “F20” dis-
plays on the coolant temperature display/
air temperature display, and its correspond-
ing stored split time displays on the stop-
watch.
3. Push the “SELECT” button to move down,
and the “RESET” button to move up
through the list.
TIP
• When displaying in the reverse chronological
order, the split times are shown from the lat-
est to earliest (i.e., L20, L19, L18, L17).
When displaying in the speed order, the split
times are shown from the fastest to slowest
(i.e., F01, F02, F03, F04).
• Push the “RESET” button for at least one
second to reset all the recorded times for the
selected split-time history.
4. Push the “SELECT” button for at least one
second to cancel the split-time history and
return to the time measurement.
1. Clock/stopwatch 1. Coolant temperature display/air intake tem-
perature display
2. Stopwatch

FEATURES
1-10
Odometer, tripmeter, instantaneous fuel
consumption and average fuel consump-
tion modes
Push the “SELECT” button to switch the dis-
play between the odometer mode “ODO”, the
tripmeter modes “TRIP 1” and “TRIP 2”, the
instantaneous fuel consumption mode “km/L”,
“L/100 km” or “MPG”, and the average fuel
consumption mode “AV_ _._ km/L”, “AV_ _._ L/
100 km” or “AV_ _._ MPG” in the following
order:
ODO →TRIP 1 →TRIP 2 →km/L, L/100 km
or MPG →AV_ _._ km/L, AV_ _._ L/100 km or
AV_ _._ MPG →ODO
If the fuel level warning light comes on, the dis-
play automatically changes to the fuel reserve
tripmeter mode “TRIP F” and starts counting
the distance traveled from that point. In that
case, push the “SELECT” button to switch the
display between the various tripmeter, odome-
ter, instantaneous fuel consumption and aver-
age fuel consumption modes in the following
order:
TRIP F →km/L, L/100 km or MPG →AV_ _._
km/L, AV_ _._ L/100 km or AV_ _._ MPG →
ODO →TRIP 1 →TRIP 2 →TRIP F
To reset a tripmeter, select it by pushing the
“SELECT” button, and then push the “RESET”
button for at least one second.
If you do not reset the fuel reserve tripmeter
manually, it resets itself automatically and the
display returns to the prior mode after refueling
and traveling 5 km (3 mi).
Instantaneous fuel consumption mode
The instantaneous fuel consumption display
can be set to either “km/L”, “L/100 km” or
“MPG”.
• When the display is set to “km/L”, the dis-
tance that can be traveled on 1.0 L of fuel
under the current riding conditions is shown.
• When the display is set to “L/100 km”, the
amount of fuel necessary to travel 100 km
under the current riding conditions is shown.
• When the display is set to “MPG”, the dis-
tance that can be traveled on 1.0 Imp.gal of
fuel under the current riding conditions is
shown.
To switch between the instantaneous fuel con-
sumption displays, push the “SELECT” button
for one second when one of the displays is
shown.
TIP
If traveling at speeds under 10 km/h (6.0 mi/h),
“_ _._” is displayed.
Average fuel consumption mode
The average fuel consumption display can be
set to either “AV_ _._ km/L”, “AV_ _._ L/100
km” or “AV_ _._ MPG”.
1. Odometer/tripmeter/fuel reserve tripmeter/
instantaneous fuel consumption/average
fuel consumption
1. Instantaneous fuel consumption
1. Average fuel consumption

FEATURES
1-11
This display shows the average fuel consump-
tion since it was last reset.
• When the display is set to “AV_ _._ km/L”, the
average distance that can be traveled on 1.0
L of fuel is shown.
• When the display is set to “AV_ _._ L/100
km”, the average amount of fuel necessary to
travel 100 km is shown.
• When the display is set to “AV_ _._ MPG”,
the average distance that can be traveled on
1.0 Imp.gal of fuel is shown.
To switch between the average fuel consump-
tion displays, push the “SELECT” button for
one second when one of the displays is shown.
To reset the average fuel consumption display,
select it by pushing the “SELECT” button, and
then push the “RESET” button for at least one
second.
TIP
After resetting an average fuel consumption
display, “_ _._” is shown for that display until
the vehicle has traveled 1 km (0.6 mi).
Transmission gear display
This display shows the selected gear.
The neutral position is indicated by “ ” and by
the neutral indicator light.
Throttle opening position display
The throttle opening position display shows
how much the throttle is being opened. The
number of segments increases as the throttle
is being opened.
Refer to “Display brightness and shift timing
indicator light control mode”.
TIP
The segments are displayed when the engine
is running.
Drive mode display
This display indicates which drive mode has
been selected: “STD”, “A” or “B”.
For more details on the modes and on how to
select them, refer to “D-mode (drive mode)”.
1. Neutral indicator light “ ”
2. Transmission gear display
1. Throttle opening position display
1. Drive mode display