Yamaha YZF-R1 2020 Manuals

Yamaha YZF-R1 2020 Manuals

Manuals and User Guides for Yamaha YZF-R1 2020. We have 1 Yamaha YZF-R1 2020 manual available for free PDF download: Service Manual

Yamaha YZF-R1 2020 Service Manual

Yamaha YZF-R1 2020 Service Manual (822 pages)

Brand: Yamaha | Category: Motorcycle | Size: 34.93 MB

Table of Contents

Table of Contents

7
- General Information
  9
  - Identification
    10
    
    Vehicle Identification Number
    10
    
    Model Label
    10
    
    Glossary
    11
    
    Display
    11
    
    Menu Screen
    15
  - Basic Service Information
    29
    
    Electrical System
    29
  - Special Tools
    30
Specifications

39
- General Specifications
  40
- Engine Specifications
  41
- Chassis Specifications
  46
- Electrical Specifications
  49
- Tightening Torques
  51
  - Engine Tightening Torques
    51
  - Chassis Tightening Torques
    53
- Cable Routing
  56
Periodic Checks and Adjustments

105
- General Maintenance and Lubrication Chart
  108
- Introduction
  108
- Periodic Maintenance
  108
- Periodic Maintenance Chart for the Emission Control System
  108
- CHECKING the FUEL LINE (Primary Injector)
  111
- CHECKING the FUEL LINE (Secondary Injector)
  111
- Checking the Vehicle Using the Yamaha Diagnostic Tool
  111
- Checking the Spark Plugs
  112
- Adjusting the Valve Clearance
  113
- Checking the Engine Idling Speed
  116
- Synchronizing the Throttle Bodies
  116
- Checking the Canister
  118
- Checking the Crankcase Breather Hose
  118
- Checking the Exhaust System
  118
- Checking the Throttle Body Joints
  118
- Adjusting the Exhaust Gas Volume
  119
- Checking the Air Induction System
  119
- Replacing the Air Filter Element
  119
- Adjusting the Clutch Lever Free Play
  120
- Checking the Brake Fluid Level
  120
- Checking the Brake Operation
  120
- Adjusting the Front Disc Brake
  121
- Checking the Front Brake Pads
  121
- Adjusting the Rear Disc Brake
  122
- Checking the Front Brake Hoses
  122
- Checking the Rear Brake Pads
  122
- Bleeding the Hydraulic Brake System (Abs)
  123
- Checking the Rear Brake Hose
  123
- Checking the Tires
  124
- Checking the Wheels
  124
- Checking the Swingarm Operation
  125
- Checking the Wheel Bearings
  125
- Drive Chain Slack
  126
- Lubricating the Swingarm Pivot
  126
- Checking and Adjusting the Steering Head
  127
- Lubricating the Drive Chain
  127
- Checking the Chassis Fasteners
  128
- Checking the Front Fork
  128
- Checking the Sidestand
  128
- Checking the Sidestand Switch
  128
- Checking the Steering Damper
  128
- Lubricating the Brake Lever
  128
- Lubricating the Clutch Lever
  128
- Lubricating the Pedal
  128
- Lubricating the Sidestand
  128
- Lubricating the Steering Head
  128
- ADJUSTING the FRONT FORK LEGS (for YZF-R1)
  129
- ADJUSTING the PRELOAD of the FRONT FORK LEGS (for YZF-R1M)
  130
- ADJUSTING the DAMPING FORCE of the FRONT FORK LEGS and REAR SHOCK ABSORBER ASSEMBLY (for YZF-R1M)
  131
- ADJUSTING the REAR SHOCK ABSORBER ASSEMBLY (for YZF-R1)
  133
- Checking the Rear Shock Absorber Assembly
  133
- ADJUSTING the PRELOAD of the REAR SHOCK ABSORBER ASSEMBLY (for YZF-R1M)
  135
- Changing the Engine Oil
  136
- Checking the Connecting Arm and Relay Arm
  136
- Checking the Engine Oil Level
  136
- Measuring the Engine Oil Pressure
  137
- Changing the Coolant
  139
- Checking the Coolant Level
  139
- Checking the Cooling System
  139
- Adjusting the Exup Cables
  141
- Adjusting the Rear Brake Light Switch
  142
- Checking the Front Brake Light Switch
  142
- Adjusting the Headlight Beams
  143
- Checking and Charging the Battery
  143
- Checking and Lubricating the Cables
  143
- Checking the Fuses
  143
- Checking the Throttle Grip
  143
Chassis

145
- General Chassis (1)
  
  151
  - Installing the Imu
    154
  - Removing the Rear Side Cover
    154
  - Removing the Tail Cover
    154
- General Chassis (2)
  
  155
  - Removing the Tail Cover
    157
  - INSTALLING the CCU (for YZF-R1M)
    157
  - CONNECTING to the CCU (for YZF-R1M)
    157
  - Installing the Tail Cover
    157
  - Installing the Rear Side Cover
    155
  - Installing the Tail Cover
    155
- General Chassis (3)
  
  158
- General Chassis (4)
  
  162
  - Removing the Front Upper Cowling
    163
  - Installing the Front Upper Cowling
    163
- General Chassis (5)
  
  164
- General Chassis (6)
  
  171
- General Chassis (7)
  
  176
- General Chassis (8)
  
  180
  - REMOVING the ECU (Engine Control Unit)
    182
  - INSTALLING the ECU (Engine Control Unit)
    182
- General Chassis (9)
  
  182
- Front Wheel
  
  184
- Rear Wheel
  
  192
- Front Brake
  
  201
- Rear Brake
  
  212
  - Introduction
    217
  - Checking the Rear Brake Disc
    217
  - Replacing the Rear Brake Pads
    217
  - Removing the Rear Brake Caliper
    218
  - Disassembling the Rear Brake Caliper
    218
  - Checking the Rear Brake Caliper
    219
  - Assembling the Rear Brake Caliper
    219
  - Installing the Rear Brake Caliper
    219
  - Removing the Rear Brake Master Cylinder
    220
  - Checking the Rear Brake Master Cylinder
    221
  - The Rear Brake Master Cylinder
    221
  - Installing the Rear Brake Master Cylinder
    221
- ABS (Anti-Lock Brake System)
  
  223
  - Abs Components Chart
    225
  - Removing the Hydraulic Unit Assembly
    226
  - Checking the Hydraulic Unit Assembly
    227
  - Checking the Brake Pipes
    227
  - Installing the Hydraulic Unit Assembly
    227
  - Hydraulic Unit Operation Test
    228
  - Checking the Abs Warning Light
    231
- Handlebars
  
  232
  - Removing the Handlebars
    235
  - Checking the Handlebars
    235
  - Installing the Handlebars
    235
- FRONT FORK (for YZF-R1)
  
  238
- FRONT FORK (for YZF-R1M)
  
  249
- Steering Head
  
  257
  - Removing the Lower Bracket
    259
  - Checking the Steering Head
    259
  - Installing the Steering Head
    260
  - Checking the Steering Damper
    260
- Rear Shock Absorber Assembly
  
  265
- Swingarm
  
  269
  - Removing the Swingarm
    271
  - Checking the Swingarm
    271
  - Installing the Swingarm
    272
- Chain Drive
  
  274
  - Removing the Drive Chain
    275
  - Checking the Drive Chain
    275
  - Checking the Drive Sprocket
    276
  - Checking the Rear Wheel Sprocket
    276
  - Checking the Rear Wheel Drive Hub
    276
  - Installing the Drive Chain
    276
  - Adjusting the Shift Pedal
    278
Engine

281
- Lubrication System Chart and Diagrams
  
  284
  - Engine Oil Lubrication Chart
    284
  - Lubrication Diagrams
    285
- Engine Inspection
  
  292
  - Measure the Compression Pressure
    292
- Engine Removal
  
  294
  - Removing the Engine
    298
  - Installing the Engine
    298
  - Installing the Exhaust Pipe and Muffler
    299
- Camshafts
  
  300
  - Engine
    305
    
    Removing the Camshafts
    306
    
    Removing the Rocker Arms and Rocker Arm Shafts
    306
    
    Checking the Camshafts
    306
    
    Checking the Rocker Arms and Rocker Arm Shafts
    308
    
    Checking the Timing Chain and Camshaft Sprocket
    308
    
    Checking the Timing Chain Guides
    308
    
    Checking the Timing Chain Tensioner
    309
    
    Assembling the Timing Chain Cover
    309
    
    Installing the Rocker Arms and Rocker Arm Shafts
    309
    
    Installing the Timing Chain Cover
    310
    
    Installing the Camshafts
    311
- Cylinder Head
  
  315
  - Removing the Cylinder Head
    316
  - Checking the Cylinder Head
    316
  - Installing the Cylinder Head
    316
- Valves and Valve Springs
  
  318
  - Removing the Valves
    320
  - Checking the Valves and Valve Guides
    320
  - Checking the Valve Seats
    322
  - Checking the Valve Springs
    324
  - Checking the Valve Spring Seat
    324
  - Installing the Valves
    324
- Generator
  
  326
  - Removing the Generator
    328
  - Installing the Generator
    328
- Starter Clutch
  
  330
  - Removing the Starter Clutch
    331
  - Checking the Starter Clutch
    331
  - Installing the Starter Clutch
    331
- Electric Starter
  
  332
  - Checking the Starter Motor
    334
  - Assembling the Starter Motor
    334
- Oil Pump
  
  336
  - Removing the Oil Pan
    339
  - Checking the Sprocket and Chain
    339
  - Checking the Oil Pump
    339
  - Checking the Relief Valve
    339
  - Checking the Oil Delivery Pipes
    339
  - Checking the Oil Strainer
    339
  - Assembling the Oil Pump
    339
  - Installing the Oil Pump
    340
  - Installing the Oil Pan
    340
- Clutch
  
  342
  - Removing the Clutch
    346
  - Checking the Friction Plates
    346
  - Checking the Clutch Plates
    346
  - Checking the Clutch Springs
    347
  - Checking the Clutch Housing
    347
  - Checking the Clutch Boss
    348
  - Checking the Pressure Plate
    348
  - Checking the Primary Drive Gear
    348
  - Checking the Primary Driven Gear
    348
  - Checking the Pull Lever Shaft and Pull Rod
    348
  - Installing the Clutch
    348
- Shift Shaft
  
  351
  - Checking the Shift Shaft
    352
  - Checking the Stopper Lever
    352
  - Installing the Shift Shaft
    352
- Crankcase
  
  353
  - Disassembling the Crankcase
    356
  - Checking the Crankcase
    356
  - Assembling the Crankcase
    356
  - Installing the Crankcase Breather Cover
    358
  - Installing the Oil Pressure Switch
    359
  - Installing the Gear Position Sensor
    359
- Connecting Rods and Pistons
  
  360
  - Removing the Connecting Rods and Pistons
    361
  - Checking the Cylinder and Piston
    362
  - Checking the Piston Rings
    363
  - Checking the Piston Pin
    364
  - Checking the Connecting Rods
    364
  - Installing the Connecting Rod and Piston
    368
- Crankshaft and Balancer Shaft
  
  373
  - Removing the Crankshaft and Balancer Shaft
    374
  - Checking the Oil Nozzles
    374
  - Checking the Crankshaft
    374
  - Checking the Balancer Shaft
    376
  - Installing the Crankshaft
    377
  - Installing the Thrust Bearing
    378
  - Installing the Balancer Assembly
    378
- Transmission
  
  380
  - Removing the Transmission
    384
  - Checking the Shift Forks
    384
  - Checking the Shift Drum Assembly
    384
  - Checking the Transmission
    385
  - Assembling the Main Axle and Drive Axle
    385
  - Installing the Transmission
    386
  - Cooling System
    389
  - Fuel System
    407
  - Electrical System
    431
  - Self Diagnostic
    487

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