Yamaha YZF-R1 User manual

Introduction

x 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.

x 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

x Please understand that these parts are not covered by warranty.

x The Manufacturer does not take any responsibility for problems caused by these parts.

Request

x These kit parts are intended exclusively for racing purposes. You are strictly requested not to

use them on public roads.

x The specifications 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

x 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.

x 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.

No. PART No. PART NAMEQ’TY REMARKS

˚ 1 4C8-11181-70 GASKET, CYLINDER

HEAD 1

3 t=0.30 mm

* 25VY-11351-00 GASKET, CYLINDER 1 3

* 34C8-11603-00 PISTON RING SET12

45VY-1165A-01 BOLT, CONNECTING ROD

SPECIAL

24

* 5 93450-18157

CIRCLIP 24

WARNING

NOTICE

TIP

CONTENTS

1 Engine Specifications................................................................................... 1

2 Kit Parts ......................................................................................................... 2

2-1 Installing Engine Parts................................................................................... 2

1. Maintenance Set (14B-MAINT-72)........................................................................ 2

2. Spark Plug Set (14B-R465B-70)........................................................................... 3

3. Head-gasket, Cylinder Gasket .............................................................................. 4

4. Piston Set (14B-116A0-70) ................................................................................... 6

5. Connecting Rod Set (14B-1165B-70) ................................................................... 6

6. Crankshaft (14B-11400-70) .................................................................................. 6

7. High-lift Camshafts................................................................................................ 7

8. Valve Spring Set (14B-A2110-72)......................................................................... 8

9. Air Funnel Set A (MGC-021008-10)...................................................................... 9

10

. Air Funnel Set B (MGC-021008-20).................................................................... 12

11. Throttle Body Clamp Set (14B-1351A-70) .......................................................... 15

12.AIS-plug Set (5VY-A4890-70)............................................................................. 16

13. Clutch Spring Set (4B1-A6330-70) ..................................................................... 18

14. Slipper Clutch Setting Set (4C8-A6377-70) ........................................................ 19

15. Transmission Gear.............................................................................................. 22

16. Mission Maintenance Set (14B-A7000-70) ......................................................... 27

17. Drive Sprockets................................................................................................... 30

18.

Sprocket Nut Set (4C8-A7463-70) ...................................................................... 31

2-2 Installing Chassis Parts............................................................................... 32

19. Oil Catcher Tank Set (14B-C1707-70)................................................................ 32

20. Shock Absorber Rear (14B-22210-70) ............................................................... 34

21. Spring Rear Shock.............................................................................................. 37

22. Machine Height Adjustment Shim Set (14B-C2127-70)...................................... 38

23. Front Fork ASSY................................................................................................. 39

24. Spring Front Fork ................................................................................................ 43

25. Seat Cushion (13S-24713-70) ............................................................................ 48

26. Front Spare Wheel ASS’Y (4C8-25100-70) ........................................................ 49

27. Rear Spare Wheel ASS’Y (4C8-25300-

70)......................................................... 50

28. Throttle Set (14B-C6300-70)............................................................................... 51

29. Throttle Set (14B-C6300-80)............................................................................... 53

30. Tube Guide (5VY-26243-80)............................................................................... 55

2-3 Installing Electrical Parts............................................................................. 56

31. ECU Set (14B-8591A-72) ................................................................................... 56

32. Cable Interface (13S-8533A-70) ......................................................................... 57

33. Wire Harness Set (14B-F2590-70) ..................................................................... 60

34. Headlight Harness Set (14B-F4350-71).............................................................. 70

35. ACM Set (14B-F1400-70) ................................................................................... 72

3 Tightening Torque List ............................................................................... 73

4 Headlight Cord Wiring Diagram................................................................. 86

5 YZF-R1 Wiring Diagram.............................................................................. 87

– 1 –

1 Engine Specifications

Spec SBK STKSTD

Displacement 998 cm³ 998 cm³ 998 cm³

Bore/Stroke 78.0 x 52.2 mm 78.0 x 52.5 mm 78.0 x 52.2 mm

Maximum engine speed

(limiter controlled speed)

13800 rpm 13800 rpm 13800 rpm

Compression ratio

(recommended value)

13.7:1

(Depend of

head-gasket

and head

cylinder

thickness and

cylinder head

surface

grinding)

12.9:1

(Depending on

the thickness of

the head

gasket)

12.7:1

Valve timing (event angle) INT. 108°103°105°

EXT. 110°103°105°

Squish height (minimum) 0.65 mm 0.

65 mm 0.75 mm

Clearance between valve

and piston (minimum)

INT. 0.9 mm

(ATDC10°)

1.0 mm

(ATDC10°)

1.3 mm

(ATDC10°)

EXT. 1.8 mm

(BTDC10°)

2.5 mm

(BTDC10°)

2.8 mm

(BTDC10°)

Valve (tappet) clearance INT. 0.17 – 0.23 mm 0.11 – 0.20 mm 0.11 – 0.20 mm

EXT. 0.27 – 0.33 mm 0.21 – 0.25 mm 0.

21 – 0.25 mm

– 2 –

2 Kit Parts

2-1 Installing Engine Parts

1. Maintenance Set (14B-MAINT-72)

These sets of parts necessary for engine disassembly and maintenance are provided in three

(3) sets.

Parts List

No. PART No. PART NAMEQ’TY REMARKS

°114B-11181-70 GASKET,

CYLINDER HEAD 1

3 t=0.30 mm

* 2 14B-11351-00 GASKET, CYLINDER 1 3 t=0.20 mm (STD)

* 3 14B-11603-00 PISTON RING SET12

45VY-1165A-01 BOLT, CONNECTING ROD

SPECIAL

24

* 5 93450-18

157 CIRCLIP 24

* 63P6-12129-00 SEAL, VALVE STEM OIL 224INT

* 74TE-12119-00 SEAL, VALVE STEM OIL 24 EXT

° 8 14B-13414-70 GASKET, STRAINER 3 OIL PAN

(

ANTI STICK

TYPE)

* 9 14B-15451-00 GSKT.,

CRANKCASE COVER 1

3 ACM (STD)

°10 14B-15461-70 GSKT.,

CRANKCASE COVER 2

3

CLUTCH (ANTI STICK TYPE)

°1114B-15456-70 GSKT., 1 3

PICK UP (ANTI STICK TYPE)

*12 14B-15462-00 GSKT.,

CRANKCASE COVER 3

3BREATHER

*1390215-30233 WASHER, TONGUE D 3SPROCKET

*1493102-40330 SEAL, OIL 3 DRIVE AXLE

*1590149-06082 SCREW 9 MAIN AXLE

*1690119-09010BOLT, HEX. W/WASHER 30 CRANK JOURNAL

*1793210-07540 O-RING 24 BALANCE

R BOLT

– 3 –

2. Spark Plug Set (14B-R465B-70)

The spark creating portion of this spark plug is of a semi-surface discharge type of shape.

TIP

Since these spark plugs have a copper gasket, caution is needed during installation on

the following points.

1. The tightening torque is 12 – 15 N•m (1.2 – 1.5 kgf•m).

2. When not checking the torque, tighten by rotating through 30° after manual

tightening in the case of new plugs. When reusing plugs, tighten by rotating through

15°.

Parts List

No. PART No. PART NAMEQ’TY REMARKS

114B-1119C-70 PLUG, SPARK 4 NGK R0465B-10

(15˚)

(30˚)

Reused

New gasket

– 4 –

3. Head-gasket, Cylinder Gasket

These parts are used to adjust the squish height and compression ratio.

They should be installed in the direction, which enables the punched alpha-numeral “14B” is

visible.

The standard head cylinder gasket thickness is 0.40 mm and the cylinder gasket thickness is

0.20 mm.

GASKET, CYLINDER HEAD

GASKET, CYLINDER

Parts List

No. PART No. PART NAMEQ’TY REMARKS

114B-11181-70 GASKET, CYLINDER HEAD 1 1 t=0.30 mm

2 14B-11181-80 GASKET, CYLINDER HEAD 1 1 t=0.35 mm

3 14B-11181-90 GASKET, CYLINDER HEAD 1 1 t=0.45 mm

4 14B-11351-70 GASKET, CYLINDE

R 1 1 t=0.10 mm

5 14B-11351-80 GASKET, CYLINDER 1 1 t=0.15 mm

Stamping location

– 5 –

Measuring the volume of the cylinder head combustion chamber

TIP

To obtain the highest performance for race use, the four cylinders should be uniform. If

you modify the head cylinder, always measure the combustion chamber volume and do

the work based on the measured value.

Measure the volume of the combustion chamber of the cylinder head (commonly called the

dome volume) as follows.

Measuring equipment

1. Burette

2. Glass plate

3. Oil (3:1 mixture of torque converter oil and white gasoline)

4. Vaseline (to seal the valve and glass plate)

Measurement method

1. Tighten a regulation spark plug to the regulation torque in the cylinder head to be

measured.

2. Set so that the alignment surface of the combustion chamber is level.

3. Apply a thin coat of Vaseline to the valve face and set the IN and EX valves.

4. Apply a thin coat of Vaseline to the combustion chamber alignment surface and set the

glass plate.

5. Add drops of oil from the burette. The total added amount is the volume of the cylinder head

combustion chamber.

– 6 –

4. Piston Set (14B-116A0-70)

Select four pistons so that the difference in their weights does not exceed 0.5g.

5. Connecting Rod Set (14B-1165B-70)

Select four connecting rod assemblies so that the difference in their weights does not exceed

2g and combine them so that the small end weights are uniform.

(by Yamaha’s measuring method)

6. Crankshaft (14B-11400-70)

Select a crankshaft with good balance.

Parts List

No. PART No. PART NAMEQ’TY REMARKS

*114B-11631-00 PISTON4

* 2 14B-11603-00 PISTON RING SET 4

* 34C8-11633-00 PIN, PISTON4

* 4 93450-18157 CIRCLIP 4

Parts List

No. PART No. PART NAMEQ’TY REMARKS

*114B-11650-00 CONN. ROD ASSY. 4

Parts List

No. PART No. PART NAMEQ’TY REMARKS

*114B-11400-00 CRANK ASSY. 1

– 7 –

7. High-lift Camshafts

This camshaft has a cam profile etc. changed from the STD one.

To adjust the valve timing, use the oval holes of the standard cam sprocket.

TIP

For valve timing adjustment, refer to the KIT TOOL MANUAL.

NOTICE

x When using this camshaft, use the valve spring set 14B-A2110-72.

x When fitting the camshaft, use the slotted holes of the cam sprockets and always set

the timing to match. If otherwise, no intended performance can be expected and

more over, the engine may be damaged.

Parts List

No. PART No. PART NAMEQ’TY REMARKS

114B-12170-71 SHAFT, CAM 1 1 IN T

2 14B-12180-71 SHAFT, CAM 2 1 EXT

90105-07006

14B-12176-00

2

1

USE THESE OVAL HOLES FOR TIMING ADJUSTMENT.

#1CAM

Cylinder head

alignment surface

Sprocket assembly position at top dead center point of #1 cylinder compression

– 8 –

8. Valve Spring Set (14B-A2110-72)

This valve spring is used when the camshaft is mounted from the kit.

NOTICE

When using this valve spring, use the camshafts 14B-12170-71, and 14B-12180-71.

The camshaft, valve spring and ECU in this set can only be used in the following combinations.

Parts List

No. PART No. PART NAMEQ’TY REMARKS

114B-12113-72 SPRING, 1 8 I.D.Color: YELLOW-

GREEN (INT)

2 14B-12114-72 SPRING, 28I.D.Color: BROWN (EXT)

CAMSHAFT VALVE SPRING ECU

2009 Models

14B-12170-70

14B-12180-70

14B-A2110-71

14B-8591A-70

1

4B-8591A-71

2010 Models

2011 Models

14B-12170-71

14B-12180-71

14B-A2110-72 14B-8591A-72

– 9 –

9. Air Funnel Set A (MGC-021008-10)

Installation

1. Installing the Plate

Secure the plate onto the throttle body.

As shown, secure the plate only at two positions below, using the supplied screws (25 mm

long).

2. Installing the Supports

Install the supports onto the levers.

Make sure to use the STD bush in the support hole.

*Use the lever and bushing intended for a STD machine.

Parts List

No. PART No. PART NAMEQ’TY REMARKS

1 PLATE L1

2 PLATE R1

3 PRIMARY FUNNEL 4 L=55 mm

4SUPPORT L 1

5SUPPORT R 1

6SHAFT ASSY. 1 Short type

7SECONDARY FUNNEL1L=60 mm

Support L

Lever Assembly

Support R

*Bush

*Bush*Lever

– 10 –

3. Installing the Lever Assembly

Secure the lever assembly onto the plates.

Using the supplied screws (30 mm long), secure the assembly at the locations as shown.

4. Installing the Primary Funnels

Secure the primary funnel by screwing it into the plate.

TIP

x For installation of the plate and funnel, apply a thin coat of grease to their screw

threads.

x For installation of the right-hand funnel, arrange the resin portion of the lever to be

located above the funnel.

5. Installing the Secondary Funnel

Install the secondary funnel onto the lever assembly.

Holes for

installation

– 11 –

6. Installing the Shaft Assembly

Install the shaft assembly that is shorter than the STD.

Start by clipping the ball joint on the electric motor side, then clip the other side of the rod to the

clip of the lever assembly.

Motor side

Clip

Ball joint

Lever side

– 12 –

10. Air Funnel Set B (MGC-021008-20)

Installation

1. Installing the Primary Funnels

Screw on the Primary funnels on the throttle body. Put only the 4 lower screws like on the

photo. Use the short screws (30 mm).

2. Installing the Supports

Install the supports onto the levers.

Don’t forget to put the plastic rings (From STD) into the holes.

Parts List

No. PART No. PART NAMEQ’TY REMARKS

1 SUPPORT L 1

2SUPPORT R 1

3 UPPER LEVER1

4 UNDER LEVER1

5 PRIMARY FUNNEL L 1

6 PRIMARY FUNNEL R 1

7SECONDARY FUNNEL1

8BOLT 4

Support R

Plastic

ring

Under lever

Upper lever

Support L

Plastic

ring

Lever Assembly

– 13 –

3. Installing the Lever Assembly

Put the screws in the holes of the supports then take the assembly previously mounted and

place them on the pins fitted in the primary funnel. (torque 10 N•m)

4. Installing the STD Connecting Rod

Start by clipping the ball joint on the electric motor side, then clip the other side of the rod to the

clip of the upper shaft.

5. Prepare the Secondary Funnel

Use the STD “seals rubber” as they are.

Holes for

installation

Clip

Ball joint

Motor side

Lever side

Plastic joints

STD “seals rubber”

– 14 –

6. Installing the Secondary Funnel

Install the secondary funnel onto the lever assembly.

Clip the secondary funnel on the 2 shafts and make sure every clips are correctly linked.

Ycci System Control

You can use the Ycci system as the kit funnel.

You can control the operation timing by using the YMS software packed together with the kit

ECU.

You can also control the STD funnel by using the YMS software.

This set is made by MG Competition. For details of the specification, please check with MG

Competition.

TEL+33 (0) 4 50 25 59 96

FAX +33 (0) 4 50 25 59 98

Web http://www.mgcompetition.fr/

– 15 –

11.Throttle Body Clamp Set (14B-1351A-70)

This part is used to enhance maintenance performance of the throttle body. Before using it, cut

off the protrusion for positioning bands at the cabjoint.

The part has a collar to prevent over-tightening. In normal cases, the part will not be tightened

till it reaches to the collar. Just manually tighten it.

Make sure to put a new band through a M5 x 0.8 tap before using it.

Parts List

No. PART No. PART NAMEQ’TY REMARKS

1 CLAMP COMP. 1 Right side (3-4)

2 CLAMP COMP. 1 Left side (1-2)

2

1

Cut it off

– 16 –

12. AIS-plug Set (5VY-A4890-70)

This plug set is used when the AIS (Air Induction System), an exhaust gas purifying system, is

removed.

Installation

1. Remove the hose attached to the cylinder head cover and the air cut-off valve

accompanying the hose.

2. Remove the cap fitted to the hose, remove the reed valve and plate from inside.

3. Install the plate (5SL-1482L-70) in replacement of the cap. Apply liquid gasket to the plate.

4. Remove the cylinder head cover and the four collars fitted to the cover. Install the PIN

(93608-16M16).

5. After removing the hose connected to the air filter casing form the air cut-off assembly,

insert the PLUG (90336-10020) onto the side of the air filter casing to close the opening.

Parts List

No. PART No. PART NAMEQ’TY REMARKS

1 5SL-1482L-70 PLATE, 22

* 2 93608-16M16 PIN, DOWEL 4

3 90336-10020 PLUG, TAPER1

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Yamaha YZF-R1 User manual

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