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 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

• 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.

No. PART No. PART NAME Q’TY REMARKS

˚ 1 4C8-11181-70 GASKET, CYLINDER 3 t=0.30mm
HEAD 1
* 2 5VY-11351-00 GASKET, CYLINDER 1 3
* 3 4C8-11603-00 PISTON RING SET 12
4 5VY-1165A-01 BOLT, CONNECTING ROD 24
SPECIAL
* 5 93450-18157 CIRCLIP 24

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.
NOTICE A NOTICE indicates special precautions that must be taken to avoid
damage to the vehicle or other property.

TIP A TIP provides key information to make procedures easier or clearer.

 CONTENTS
1 Engine Specifications.................................................................................. 1
2 Kit Parts......................................................................................................... 2
2-1 Installing Electrical Parts...............................................................................2
1. ECU Set (BX4-8591A-71)....................................................................................2
2. Cable Interface (2CR-8533A-70)......................................................................... 4
3. Wire Harness Set (BX4-F2590-70)..................................................................... 6
4. Headlight Harness Set (BX4-F4350-70)............................................................ 18
5. Repair set ......................................................................................................... 19
6. CCU COMP. (2KS-85800-71)............................................................................ 20

2-2 Installing Engine Parts.................................................................................25

7. Maintenance Set (2CR-MAINT-72).................................................................... 25
8. Spark Plug Set (14B-R465B-70).......................................................................26
9. Piston Set (2CR-116A0-71)................................................................................ 27
10. Connecting Rod Set (2CR-1165B-70)................................................................ 27
11. Crankshaft (2CR-11400-71)............................................................................... 27
12. High-lift Camshafts, Cam Sprocket...................................................................29
13. Valve Spring Set (2CR-A2110-71)..................................................................... 32
14. Air Funnel Set (2CR-1440B-70).........................................................................33
15. AIS-plug Set (2CR-A4890-80)..........................................................................35
16. Transmission Gear............................................................................................36
17. Mission Maintenance Set (2CR-A7000-70).......................................................39
18. Drive Sprockets................................................................................................. 42
19. Sprocket Nut Set (2CR-A7463-70)....................................................................43
20. Strainer Cover Set (2CR-13400-71)...................................................................44

2-3 Installing Chassis Parts...............................................................................49

21. Spring Rear Shock............................................................................................ 49
22. Spring Front Fork..............................................................................................50
23. Seat Cushion (13S-24713-70)............................................................................ 52
24. Front Spare Wheel ASS’Y (2CR-25100-70)......................................................53
25. Rear Spare Wheel ASS’Y (2CR-25300-70)......................................................54
26. Tube Guide (2CR-26243-70).............................................................................55

3 Tightening Torque List............................................................................... 56

Tightening the Cylinder Head....................................................................................69
Installing the Crankcase............................................................................................ 70
Procedure to tighten the aluminum bolts................................................................... 71
When replacing aluminum bolts with iron bolts......................................................... 72
Procedure to install the engine.................................................................................. 73
Procedure to install the pivot shaft peripheral parts.................................................. 74

4 Headlight Cord Wiring Diagram................................................................ 75

5 YZF-R1 Wiring Diagram............................................................................. 76
R1YEC20181105Rev
1 Engine Specifications
Spec SBK/JSB STK STD
3 3
Displacement 998cm 998cm 998cm3
Bore/Stroke 79.0 × 50.9 mm 79.0 × 50.9 mm 79.0 × 50.9 mm
Maximum engine speed 14750 rpm 14500 rpm 14500 rpm
(limiter controlled speed)
Compression ratio 13.0 – 13.4 13.0 13.0
(recommended value) Depending on
head surface
grinding
Valve timing (event angle) INT 105° 108° 108°
EXT 108° 110° 110°
Clearance between valve INT 0.95 mm – –
and piston (minimum) 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
R1EN20181211Rev

–1–
2 Kit Parts
2-1 Installing Electrical Parts
1. ECU Set (BX4-8591A-71)

Parts List
No. PART No. PART NAME Q'TY REMARKS
1 BX4-8591A-71 ECU 1
2 BX4-2818Y-72 CD 1 YMS SOFT & MANUAL '19 Ver.
R1EN11052018Rev

• Use of this set and a wire har ness <Setting-up Details>

included in the kit enables regulation (or STK specification:
setting) of fuel injection and ignition timing, Base Data for STK
etc. (R1-19_BaseData_00_STK.ycz)
• For details as to how to regulate (or set) Kit harness STK / SBK switching 2
fuel injection and ignition timings, etc., pole connector: Disconnected state .
and the method of writing the base data, *Recommended muffler
refer to the FI matching system manual in
the CD-ROM that comes with the set. SBK specification:
• At shipment, the base data for STK (stock Base Data for SBK
sports) (R1-19_BaseData_00_STK.ycz) is (R1-19_BaseData_00_SBK.ycz)
written in ECU of this set. The base data Kit cam shaft, Kit valve spring, Kit air
for STK is for the standard engine. When funnel set, *Recommended muffler.
using with SBK (super motorbike), please Kit harness STK / SBK switching 2
write SBK base data (R1-19 _BaseData _ 00 pole connector: Connected state.
_ [Link]) with FI matching system. SBK
control data is for modified engine. * Recommended muffler
When using it with STK please remove the Made by Akrapovic (For details of the
2 pole coupler of the kit harness located at specification, please access the website.)
the lower left of the fuel tank . When using Web [Link]
with SBK please use with 2 pole coupler intro?returnUrl=%2F
connected. At shipment the coupler is
R1EN11052018Rev

connected. (See the figure below)

R1EN11052018Rev

NOTICE
Before using the KIT ECU for the first
time, use YMS to perform writing of the
base map.

–2–
The set of the camshaft, valve spring, ECU
and air funnel must be used in the following
combination.

R1YEC20181019Rev

NOTICE

Using in other combinations may possibly

damage the engine.
Be sure to use in the combination as
stated above.

–3–
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-71 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.

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.

2015 to 2017 models

You can check the following codes on the meter
(2CR/2KS-28130-70).

2018,2019model
To check the following codes, connect an OBD
tool (commercially available) to the vehicle using
the genuine Yamaha part "90890-03249 OBD/
GST LEADWIRE KIT".
You can purchase "90890-03249 OBD/GST
LEADWIRE KIT" at any Yamaha part dealer.
R1EN11052018Rev

–4–
 2015~2017 2018
Malfunction
CODE Description DTC CODE DTC English name / check item mode
Open circuit /
8 Gear position sensor malfunctions P0916 Gear Shift Position Circuit Low short circuit

8 Gear position sensor malfunctions P0917 Gear Shift Position Circuit High Supply fault

11 Cam angle sensor malfunctions P0340 Camshaft Position Sensor "A" Circuit Bank 1 or Single Sensor Disabled

12 Cylinder angle sensor malfunction P0335 Crankshaft Position Sensor "A" Cirouit Disabled

Intake pressure sensor malfunctions

13 (open circuit / short circuit)
P0107 Manifold Absolute Pressure/BarometricPressure Sensor Circuit Low Ground fault

Intake pressure sensor malfunctions Open circuit /

13 (open circuit / short circuit)
P0108 Manifold Absolute Pressure/Barometric Pressure Sensor Circuit High supply fault
Throttle opening sensor malfunctions
15 (open circuit / short circuit / ETV)
P0122 Throttle/Pedal Position Sensor/Switch "A" Clrcuit Low Ground fault

Throttle opening sensor malfunctions Open circuit /

15 (open circuit / short circuit / ETV)
P0123 Throttle/Pedal Position Sensor/Switch "A" Clrcuit High
supply fault
Throttle opening sensor malfunctions
15 (open circuit / short circuit / ETV)
P0222 Throttle/Pedal Position Sensor/Switch "B" Circuit Low
Ground fault
Throttle opening sensor malfunctions Open circuit /
15 (open circuit / short circuit / ETV)
P0223 Throttle/Pedal Position Sensor/Switch "B" Circuit High
supply fault
Throttle opening sensor malfunctions
15 (open circuit / short circuit / ETV)
P2135 Throttle/Pedal Position Sensor/Switch "A" / "B" Voltage Correlation Deviation fault

Intake pressure sensor or atmospheric

20 pressure sensor malfunctions
P0069 Manifold Absolute Pressure - Barometric Pressure Correlation Incompatibility

Intake pressure sensor or atmospheric

20 pressure sensor malfunctions
P1004 Manifold Absolute Pressure - Cylinder Idenfification MAP Correlation Incompatibility

Water temperature sensor malfunctions (open

21 circuit / short circuit)
P0117 Engine Coolant Temperature Sensor 1 Circuit Low Ground fault

Water temperature sensor malfunctions (open Open circuit /

21 circuit / short circuit)
P0118 Engine Coolant Temperature Sensor 1 Circuit High
supply fault
Intake temperature sensor malfunctions
22 (open circuit / short circuit)
P0112 Intake Air Temperature Sensor 1 Circuit Low Bank 1 Ground fault

Intake temperature sensor malfunctions Open circuit /

22 (open circuit / short circuit)
P0113 Intake Air Temperature Sensor 1 Circuit High Bank 1
supply fault
Atmospheric pressure sensor
23 malfunctions (open circuit / short circuit)
P2228 Barometric Pressure Sensor "A" Circuit Low Ground fault

Atmospheric pressure sensor Open circuit /

23 malfunctions (open circuit / short circuit)
P2229 Barometric Pressure Sensor "A" Circuit High
supply fault

33 Ignition coil #1 malfunctions (open circuit) P0351 Ignition Coil "A" Primary Control Circuit/Open Disabled

34 Ignition coil #2 malfunctions (open circuit) P0352 Ignition Coil "B" Primary Control Circuit/Open Disabled

35 Ignition coil #3 malfunctions (open circuit) P0353 Ignition Coil "C" Primary Control Circuit/Open Disabled

36 Ignition coil #4 malfunctions (open circuit) P0354 Ignition Coil "D" Primary Control Circuit/Open Disabled

Injector (primary) malfunctions

39 (open circuit)
P0201 Cylinder 1 Injector "A" Circuit Disabled

42 Rear wheel sensor malfunctions P0500 Vehicle Speed Sensor "A" Cirouit No signals

Battery voltage monitor malfunctions

43 (power source for fuel system)
P0657 Actuator Supply Voltage "A" circuit/Open Abnormity

44 EEPROM malfunctions P062F Internal Control Module EEPROM Error Writing error

ECU malfunctions
45 (electrical power system)
P1602 Internal Control Module Shutoff Circuit Abnormity

46 Power source for vehicle malfunctions P0560 System Voltage Abnormity

50 ECU internal malfunctions P0601 Internal Control Module Memory Checksum Error Checksum error

Communication
50 ECU internal malfunctions P0606 Control Module Processor fault between
CPUs

Open circuit /
59 Accelerator opening sensor alfunctions P2122 Throttle/Pedal Position Sensor/Switch "D" Circuit Low
ground fault
(open circuit / short circuit)
Accelerator opening sensor alfunctions
59 (open circuit / short circuit)
P2123 Throttle/Pedal Position Sensor/Switch "D" Circuit High Supply fault

Accelerator opening sensor alfunctions

59 (open circuit / short circuit)
P2127 Throttle/Pedal Position Sensor/Switch "E" Circuit Low Ground fault

Accelerator opening sensor alfunctions Open circuit /

59 (open circuit / short circuit)
P2128 Throttle/Pedal Position Sensor/Switch "E" Circuit High
supply fault
Accelerator opening sensor alfunctions
59 (open circuit / short circuit)
P2138 Throttle/Pedal Position Sensor/Switch "D" / "E" Voltage Correlation Deviation fault

Throttle motor malfunctions

60 (drive system)
P0638 Throttle Actuator Control Range/Perfomance Bank 1 Disabled

69 Front wheel sensor malfunctions P2158 Vehicle Speed Sensor "B" Cirouit No signals

Implemetation
70 Engine stop by idling away P1E70 YDT event judgment

98 IMU malfunctions (main unit) C0520 Multi-axis Acceleration Sensor Module "A" Abnormity

IMU malfunctions
99 (communication system)
U0125 Lost Communication With Multi-axis Acceleration Sensor Module Time out

–5–
3. Wire Harness Set (BX4-F2590-70)

Parts List
No. PART No. PART NAME Q'TY REMARKS
1 BX4-82590-70 WIRE HARNESS ASSY. 1 MAIN HARNESS
° 2 2CR-82386-70 WIRE,SUB-LEAD for TH INJECTOR 1 TH INJECTOR
° 3 2CR-82318-70 WIRE,SUB-LEAD for AC INJECTOR 1 AC INJECTOR
° 4 2CR-82309-70 WIRE,SUB-LEAD for IG. COIL 1 IGNITION COIL
° 5 2CR-8231Y-70 WIRE,LEAD for FUEL PUMP 1 FUEL PUMP
° 6 2CR-83553-70 WIRE,LEAD for METER 1 METER
7 2CR-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-10 CORD COMP. 1
* 18 5GF-83976-00 [Link] 1 1 TAIL LIGHT SW

This wire harness is weight-saved by doing

away with connecting wires for lights.
This wire harness will not function unless
it is combined with the kit's ECU (BX4-
8591A-70,71).
R1EN11052018Rev

–6–
WIRE, SUB-LEAD

Parts List
No. PART No. PART NAME Q'TY REMARKS
20 2KS-82509-70 WIRE, SUB-LEAD 1 SCU
This wire harness is for mounting the KIT
harness to a vehicle with the Electric racing
suspension (ERS) function.

TIP
If the E-SD (STD steering damper) is not
used, removing its coupler will pose no
problem.

NOTICE

• Before using the KIT ECU for the first

time, use YMS to perform writing of
the base map.
• Remove the coupler of the main switch
before starting assembling work.

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.
• Be sure to connect the Hydraulic unit
assy. to the wire harness. The ABS
does not function when using the KIT
ECU, but every electronic control does
not work without the connection.

R1EN11052018Rev

–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

R6
3

20

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 7 seat).

22
R20

44
102
0
R2

49

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 7 inward
and tighten them together with the shaped
side cover.

8 7
9

10

11

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.
VI MOTOR

TPS

[Link] SENSOR 7 2CR-2128A-70

APS BRKT., REGULATOR 1
THROTTLE MOTOR
PRESSURE SENSOR(Pa) 20 2KS-82509-70
PRESSURE SENSOR(Pb) WIRE, SUB-LEAD

E-SD SOLENOID 2KS STD RCU

2KS STD SUB LEAD FUSE BOX1

[Link] SENSOR
MAIN SW ABS ECU
IMU
6 2CR-83553-70 ECU1/2
WIRE,LEAD for METER ST RELAY1
RELAY ASSY.
POWER SUPPLY

PC I/F
METER
AIR TEMP SENSOR LIGHT SW

CRANK SHAFT SENSOR

HANDLE SW LH&RH

POWER SUPPLY 2
ACM
2KS SUB LEAD
OIL SW

METER SUB LEAD SHIFT SENSOR

SELECT SW
REC/REGU

, indicate the names of parts to be connected.

– 10 –
METER MAIN SW

AIR TEMP SENSOR

[Link] SENSOR HANDLE SW LH

APS HANDLE SW RH
THROTTLE MOTOR POWER SUPPLY 2
PRESSURE SENSOR(Pa) 2KS SUB LEAD
PRESSURE SENSOR(Pb) MAIN SW
VI MOTOR E-SD SOLENOID

METER SUB LEAD 3 2CR-82318-70

2CR-82386-70
REC/REGU WIRE,SUB-LEAD
TPS for AC INJECTOR
SELECT SW INJECTOR #12/22/32/42
SHIFT SENSOR
OIL SW FUEL PUMP

CRANK SHAFT SENSOR WATER TEMP SENSOR

[Link] 1/2/3/4
ACM CAM SENSOR

LIGHT SW

4 2CR-82309-70
2CR-82386-70
WIRE,SUB-LEAD
WIRE,SUB-LEAD
for [Link]
for IG. COIL
2 2CR-82386-70
WIRE,SUB-LEAD
for TH INJECTOR

INJECTOR #11/21/31/41
FUSE BOX1
[Link] SENSOR NEUTRAL SW
ABS ECU
IMU EG EARTH
ECU1/2
ST RELAY1 PC I/F
RELAY ASSY.
POWER SUPPLY

– 11 –
PRESSURE SENSOR(Pa) [Link] SENSOR

VI MOTOR APS

PRESSURE SENSOR(Pb) THROTTLE MOTOR

, indicate the names of parts to be connected.

– 12 –
 12 2KS-2161E-70
BRKT.,4
ECU2 RELAY ASSY.

ST RELAY IMU

POWER SUPPLY ABS ECU

TAIL LIGHT [Link] SENSOR

ECU1 FUSE BOX1

, indicate the names of parts to be connected.

MAIN FUSE

– 13 –
The name and function of each switch
<Left>
Keep the switch at low position
Hi position→the LAP switch becomes non-functional
Mode switch Up button

LAP switch
Center button

Down button

Not used

Pit road limiter MAP SELECT

ON ON →MAP 1
PUSH=OFF →MAP 2

<Right>
Starter switch/Engine stop switch

Wheel switch

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

– 15 –
SCS : Slide control system LIF : Lift control system
The slide control system controls engine The lift control system reducing wheel lift rate
power output when a sideward slide is during extreme acceleration, such as during
detected in the rear wheel. starts or out-of-corner acceleration.
It adjusts output to an optimum level based When front-wheel lift is detected by the IMU,
on data from the IMU, thus helping the rider engine output is adjusted to the optimum
focus on riding without distraction. level to compensate for it and thus assist the
This system supports the TCS to contribute rider’s vehicle control.
to a smoother ride.
Strong 3
Strong 3 2
2 1
1 Control ratio
Control ratio

Weak
Weak Slow Fast
Slow Fast Front-wheel lift speed
Side slide speed
ERS : Electronic racing suspension
LCS : Launch control system
The Ohlins electronic racing suspension takes
The launch control system helps ensure
data from the IMU and the suspension control
smooth and swift starts.
unit (SCU) makes integrated adjustments of
The LCS maintains an optimum level of
both the front and rear suspension’s damping
engine output in conjunction with input from
force based on running conditions.
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.

– 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.
40×4±0.05
(when D=Φ90: 4 mm, when D=Φ180: 8 mm)
Holes (40 locations) (40
pa 2CR-85970-00
equ rts
18 tion or
i s

iang
40×8±0.2

FR. WHEEL SENSOR ASSY.

0 os n

ular
(9 g p t se

ly)
2CR-85980-00
0)
a
Φ ctin er
(4)

RR. WHEEL SENSOR ASSY.

te et

–
de iam

t2
D

ROTOR, SENSOR
10
0°
direction
Rotation

14±0.1
Center of sensor .3
0.8 – 2
D/2±0.2

+0.1
ROTOR, SENSOR Φ11.8 0 M6×1.0
Sensor mount Reference shape

THIRD ANGLE PROJECTION METHOD

– 17 –
4. Headlight Harness Set (BX4-F4350-70)

Parts List

No. PART No. PART NAME Q'TY REMARKS

1 BX4-84359-70 CORD, HEAD LIGHT 1
* 2 5GF-83976-00 SW., HANDLE 1 3 Light ON/OFF SW. x 2
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.

There are three light switches.

SW.1 : Turns on the headlight (high beam) and
taillight 1
SW.2 : Turns on the headlight (low beam) and
taillight 2
EMERGENCY SW. : Turns on the emergency
light

Use the appropriate light according to the

racing rules of the endurance race.

(Diagram)

– 18 –
5. Repair set (2CR-28130-70,BX4-28130-80 ,2KS-28130-70 ,2KS-28130-80)
Select the part set corresponding to your
model.

Parts List
2CR-28130-70 (for 2015 to 2017 YZF-R1(2CR/BX41))
No. PART No. PART NAME Q'TY REMARKS
° 1 2CR-83500-00 METER ASSY. 1
° 2 2CR-83963-00 SWITCH HANDLE 3 1
° 3 2CR-83969-00 SWITCH HANDLE 5 1
° 4 2CR-85970-00 [Link] SENSOR 1
° 5 2CR-85980-00 [Link] SENSOR 1

Parts List
BX4-28130-80 (for 2018 and 2019 YZF-R1(BX46/BX4D))
No. PART No. PART NAME Q'TY REMARKS
° 1 BX4-83500-30 METER ASSY. 1
° 2 2CR-83963-00 SWITCH HANDLE 3 1
° 3 2CR-83969-00 SWITCH HANDLE 5 1
° 4 2CR-85970-00 [Link] SENSOR 1
° 5 2CR-85980-00 [Link] SENSOR 1
R1EN11052018Rev

Parts List
2KS-28130-70 (for 2015 to 2017 YZF-R1M(2KS))
No. PART No. PART NAME Q'TY REMARKS
° 1 2KS-83500-00 METER ASSY. 1
° 2 2CR-83963-00 SWITCH HANDLE 3 1
° 3 2CR-83969-00 SWITCH HANDLE 5 1
° 4 2CR-85970-00 [Link] SENSOR 1
° 5 2CR-85980-00 [Link] SENSOR 1
R1EN11052018Rev

Parts List
2KS-28130-80 (for 2018 and 2019 YZF-R1M(2KS))
No. PART No. PART NAME Q'TY REMARKS
° 1 2KS-83500-60 METER ASSY. 1
° 2 2CR-83963-00 SWITCH HANDLE 3 1
° 3 2CR-83969-00 SWITCH HANDLE 5 1
° 4 2CR-85970-00 [Link] SENSOR 1
° 5 2CR-85980-00 [Link] SENSOR 1
R1EN11052018Rev

– 19 –
6. CCU COMP. (2KS-85800-71)

The CCU (Communication control unit) The CCU of R ACING KIT PARTS is
facilitates checking or settings of the vehicle equipped with the general-purpose analog
information, and enhances rider's relationship voltage (0 to 5 V) interface.
with the vehicle.
The CCU COMP. consists of the CCU ASSY. For information about the standard features,
and GPS unit. refer to the OWNER'S MANUAL for the
Download the application onto the tablet vehicle or the explanation of the store
before use. application in addition to this manual.
R1180501Rev

Parts List
No. PART No. PART NAME Q'TY REMARKS
1 2KS-85810-71 CCU ASSY. 1 dedicated software
embedded
* 2 2KS-88107-00 GPS unit 1
3 2KS-85721-70 Sub-harness 1
Application Download from App
Store/Google Play Store

CCU Compatibility chart

PART No. MODEL

2015 to 2017 2018,2019
2KS-85800-70
✓ ✖
2KS-85800-71 ✓ ✓
R1EN11052018Rev

Components Sub-harness
CCU ASSY.
(dedicated software embedded)

Application
GPS unit Download from App Store/Google Play Store

TIP
The functions of the CCU unit
• Data logging (GPS positioning
information, vehicle information, analog
voltage)
• Line passing detection
• Wireless LAN main unit (IEEE 802.11b/g/n)
– 20 –
Preparation TIP
• Install the units to the vehicle. When using it for the first time, check
if the GPS icon lights up on the meter
TIP
before riding.
The gray and black cable is for AIN-1 (It may take about 10 minutes for GPS
(analog Ch1), and the purple and black positioning even in an outdoor location.)
cable is for AIN-2 (analog Ch2).
LCS QS LIF A-1 GPS 12 : 00
× 1000 r/min

TIP
Since the eight-digit number (S/N:) on the
CCU unit will be used as the password km/h

for wireless LAN connection between the

tablet and CCU, be sure to write down the
ODO
TRIP-2

MODE-A
12345 km
1234.5 km
PWR 1
1 N2
TCS 1 SCS 1
number.
Since the GPS and oil-pressure warning
icons are at the same location, the GPS
icon does not light up when the the oil-
pressure warning icon lights up (such as
engine stop).
LCS QS LIF A-1 12 : 00
× 1000 r/min

12 34 12
N
LATEST GEAR

LAP 09

123 km/h
ODO 7890
km
MODE-A PWR 1 TCS 1 SCS 1

NOTICE
If GPS positioning is not available, it will
affect functioning of logging.

• Download the application onto the tablet.

TIP
For Android, visit Google Play Store and
download "Y-TRAC" and "CCU Config".

For iOS, visit App Store and download

"Y-TRAC". (Y-TRAC is equipped with the
CCU Config feature.)

In this manual, iOS version screens are

used as examples.

– 21 –
Usage
Operations on the tablet Application to be used Network to
be connected
Before riding Draw a circuit record line on the map. CCU Config Internet
(See Fig. 1.) (Y-TRAC for iOS version)
Transfer the record line to the CCU. CCU Config CCU
(Y-TRAC for iOS version)
Set the logging mode of the CCU to CCU Config CCU
"Track". (See Fig. 2.) (Y-TRAC for iOS version)
While riding
After riding Download the logging data from the Y-TRAC CCU
CCU.
Display the logging data (with map). Y-TRAC Internet

(Fig. 1.) (Fig. 2.)

TIP
When connecting the tablet to the network,
select CCU (when communicating with
the CCU) or Internet (when displaying the
map) according to the use.

Connecting to the CCU Label on the CCU (See Fig.3.)

Network name (SSID) YAMAHA MOTOR CCU ddeeff MAC: aa-bb-cc-dd-ee-ff
Password 12345678 S/N: 12345678

(Fig. 3.)

– 22 –
TIP <Example 1>
When the following is stated in the
When viewing logging data, analog Ch is
not displayed by Y-TRAC default setting. sensor's manual
To display it, tap Graph Setting in the "AF value: voltage x 1.6 +10"
Graph Option mode. Factor 1.6000
Offset 10.0000
Min Y-axis 10.00
Max Y-axis 20.00
(Min Y-axis and Max Y-axis can be any
given values)

<Example 2>
When the following is stated in the
sensor's homepage
"Output voltage is three times the λ value."
↓
On the screen, tap AIN-1 or AIN-2 to AF value: output voltage x 14.7 / 3
display the arbitrary CH. Factor 4.9000
Offset 0.0000
Min Y-axis 10.00
Max Y-axis 20.00
(Min Y-axis and Max Y-axis can be any
given values)

In the analog display mode, the voltage is

indicated by level (0 to 5) by default. The
display value can be changed according
to the specif ication of the installed
sensor. To change the display value, tap
AIN Setting.

– 23 –
Other usages
Meter setting
To indicate CCU's detection of line passing
on the meter, enable the stop watch function
on the meter (blink ":" (column) and "." (period)
in area 2).

2
QS LIF A-2 GPS 12 : 00
× 1000 r/min

03 06 40
N
LATEST GEAR

LAP 03

123 7890
ABERAGE
ODO
km/h km
MODE-A PWR 1 TCS 3 SCS 2

1
<Wheel switch operation procedure>
Press the wheel switch to blink area 1.
↓
Rotate the wheel switch to blink area 2.
↓
Press and hold the wheel switch to blink only
":" (column) and "." (period) in area 2.

This operation is required each time after the

main switch is set to ON.

TIP
Regardless of the meter setting, lap data
will be recorded in the logging data when
line passing is detected,

– 24 –
2-2 Installing Engine Parts
7. Maintenance Set (2CR-MAINT-72)

Parts List
No. PART No. PART NAME Q'TY REMARKS
* 1 2CR-11181-00 GASKET, CYLINDER HEAD 1 3 t=0.20 mm (STD)
* 2 2CR-11351-00 GASKET, CYLINDER 1 3 t=0.20 mm (STD)
* 3 2CR-11603-10 PISTON RING SET 12
* 4 2CR-1165A-00 BOLT, CONNECTING ROD SPECIAL 24
* 5 93450-18169 CIRCLIP 24
* 6 3P6-12129-00 SEAL, VALVE STEM OIL 2 24 INT
* 7 4TE-12119-00 SEAL, VALVE STEM OIL 24 EXT
* 8 BX4-13414-00 GASKET, STRAINER 3 OIL PAN
° 9 2CR-15451-70 GSKT., CRANKCASE COVER 1 3 CLUTCH
° 10 2CR-15461-70 GSKT., CRANKCASE COVER 2 3 CLUTCH
° 11 2CR-15456-70 GSKT., 1 3 PICK UP
* 12 2CR-15462-00 GSKT., CRANKCASE COVER 3 3 BREATHER
* 13 93102-40330 SEAL, OIL 3 DRIVE AXLE
* 14 90149-06082 SCREW 9 MAIN AXLE
* 15 90119-09010 BOLT, HEX. W/WASHER 30 CRANK JOURNAL BOLT
* 16 93210-07540 O-RING 24 BALANCER BOLT
R1EN11052018Rev

These sets of parts necessary for engine

disassembly and maintenance are provided in
three (3) sets.

– 25 –
8. Spark Plug Set (14B-R465B-70)

Parts List

No. PART No. PART NAME Q'TY REMARKS

1 14B-1119C-70 PLUG, SPARK 4 NGK R0465B-10

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° .

– 26 –
9. Piston Set (2CR-116A0-71)

Parts List
No. PART No. PART NAME Q'TY REMARKS
* 1 2CR-11631-10 PISTON 4
* 2 2CR-11603-10 PISTON RING SET 4
* 3 2CR-11633-00 PIN, PISTON 4
* 4 93450-18169 CIRCLIP 8

This set consists of a combination of four

genuine pistons so that the weight difference
of each item does not exceed 0.5 g.

10. Connecting Rod Set (2CR-1165B-70)

Parts List
No. PART No. PART NAME Q'TY REMARKS
* 1 2CR-11650-00 CONN. ROD ASSY. 1 4

This set consists of four genuine connecting

rod assemblies and the weight difference of
each item does not exceed 2 g and combine
them so that the small end weights are
uniform.(by Yamaha’s measuring method)

11. Crankshaft (2CR-11400-71)

Parts List
No. PART No. PART NAME Q'TY REMARKS
* 1 2CR-11400-10 CRANK ASSY. 1

This item is a genuine crankshaft with good

balance.

– 27 –
About compatibility between the piston
set, connecting rod set and crankshaft
(by model year)
MODEL Piston set Connecting Rod Set Crankshaft
2015 2CR-116A0-70 2CR-11400-70
2016
2017 2CR-1165B-70
2CR-116A0-71 2CR-11400-71
2018
2019
R1EN11052018Rev

Piston set:
As the component parts (piston and piston
ring) of the 2016 to 2019 models are different
from that of the 2015 model, the 2015 model
and 2016 to 2019 models are not compatible
each other.
Be sure to use a combination of a piston and
a piston ring of same model year.
Since the piston set of the kit consists of
pistons, piston rings and piston pins, the set
enables installing those items on any model-
year engine at once.

Connecting rod:
No change.

Crankshaft:
As a thrust bearing is added to the #4 cylinder
for the 2016 to 2019 model engine, the 2015
model and 2016 to2019 models are not
compatible each other.
The 2015 model crankshaft is currently not
available in the kit.
Please purchase a Yamaha genuine part
when a 2015 model crankshaft is needed.
R1EN11052018Rev

– 28 –
12. High-lift Camshafts, Cam Sprocket

High-lift Camshafts INT (2CR-12170-70)

Parts List
No. PART No. PART NAME Q'TY REMARKS
1 2CR-12170-70 SHAFT, CAM 1 1 INT
R1EN11052018Rev

High-lift Camshafts EXT (2CR-12180-70)

Parts List
No. PART No. PART NAME Q'TY REMARKS
2 2CR-12180-70 SHAFT, CAM 2 1 EXT
R1EN11052018Rev

Cam Sprocket
Parts List

No. PART No. PART NAME Q'TY REMARKS

3 2CR-12176-70 SPROCKET, CAM 1 INT/EXT-shared use
4 0WU7-90064-00 BOLT,SPROCKET 2
R1EN11052018Rev

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

Tightening torque 24±2Nm

R1EN11052018Rev

Possible to adjust the valve timing using the

long holes on the cam sprocket.

USE THESE OVAL HOLES FOR

TIMING ADJUSTMENT.

The set of the camshaft, valve spring, ECU

and air funnel must be used in the following
combination.
– 29 –
NOTICE
Using in other combinations may possibly
damage the engine.
Be sure to use in the combination as
stated below.

R1YEC20181019Rev

– 30 –
Installation
1. Fit the scratch line on the camshaft to the TIP
compression top dead point 105 degree (K Install the cam sprocket as the scratch
mark position) to combine the camshaft line and 2CR mark face the outside of the
and cylinder head surface. engine.
2. Adjust the valve timing (to the value stated
on the normal specifications) using the
long holes.
<How to position at #1 cylinder’s compression top dead point 105°>

Fit the assembly (K) mark of the rotor

assembly to the case surface line.
(#1 cylinder compression top dead
point 105 degree)

< Position to install the cam sprocket at #1 cylinder compression top dead point 105°>
Tighten using the long holes on the cam sprocket.
Exhaust #1 cam nose
Intake valve timing mark
Exhaust valve timing mark
(Scratch line)
(Scratch line)

Intake #1 cam nose

Exhaust side

#1 #2 #3 #4
Intake side

NOTICE

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.

– 31 –
13. Valve Spring Set (2CR-A2110-71)

Parts List

No. PART No. PART NAME Q'TY REMARKS

1 2CR-12130-70 SPRG' ASSY. 1 8 [Link]: Blue (INT)
2 2CR-12140-70 SPRG' ASSY. 2 8 [Link]: Red (EXT)
* 3 2CR-12117-00 [Link] SPRING 8 INT
* 4 2CR-12127-00 [Link] SPRING 2 8 EXT

This valve spring is used when the camshaft

is mounted from the kit.

This set consists of a valve spring, a valve

spring seat and a retainer valve spring.
While the valve spring of the 2017 model
employs double-spring structure, that of the kit
parts employs single-spring structure.
When applying this set to the 2017 to 2019
model, replace whole corresponding parts with
this set.
When applying this set to the 2015 and 2016
model, you do not need to replace with the
retainer valve spring of this set (installation is
possible).

The set of the camshaft, valve spring, ECU

and air funnel must be used in the following
combination.

R1YEC20181019Rev

NOTICE

Using in other combinations may possibly

damage the engine.
Be sure to use in the combination as
stated above.

– 32 –
14. Air Funnel Set (2CR-1440B-70)

Parts List
No. PART No. PART NAME Q'TY REMARKS
1 2CR-14479-70 SECONDARY FUNNEL 1
2 2CR-14469-70 PRIMARY FUNNEL 1 1
3 92014-06025 BUTTON HEAD BOLT 3
4 2CR-1446C-70 PRIMARY FUNNEL 2 1
5 92014-06025 BUTTON HEAD BOLT 3
Installation TIP
1. Assembling the primary funnel
The STD seal rubber is not used at the
Secure the primary funnel 1 and 2 to the
bottom sur face (face to the primar y
throttle body with the supplied button head
bolts. At this time, install the STD lever 1 and funnel) of the secondary funnel.
2 and fix them.
Lever 1 Lever 2 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.

2. Assembling the secondary funnel

Install the secondary funnel to the lever 1
and 2. Then, fit the STD bushes to the lever
assembling positions. (5 locations)
Bush (5 locations)

– 33 –
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 below.

R1YEC20181019Rev

– 34 –
15. AIS-plug Set (2CR-A4890-70)

This plug set is used when the AIS (Air

Induction System), an exhaust gas purifying
system, is removed.
Parts List
No. PART No. PART NAME Q'TY REMARKS
1 5SL-1482L-70 PLATE, 2 2
2 2CR-11159-70 PLUG, BLIND 4
3 90336-10020 PLUG, TAPER 1

Installation
1. Remove the hose attached to the cylinder 4. Remove the cylinder head cover and the four
head cover and the air cut- of f valve collars fitted to the head cover, and install
accompanying the hose. the 2 PLUG, BLIND (2CR-A4890-70).
2. Remove the cap fitted to the hose, remove 5. After removing the hose connected to
the reed valve and plate from inside. the air filter casing form the air-cut valve
3. Install the 1 PLATE,2 (5SL-1482L-70) in assembly, insert the 3 PLUG, TAPER
replacement of the cap. Be sure to apply (90336-10020) onto the side of the air
liquid gasket. filter casing to close the opening.
STD

A
KIT

B 3 1

B B-B

2 A
– 35 –
16. Transmission Gear

Parts List
No. PART No. PART NAME Q'TY REMARKS
1 2CR-17401-70 MAIN AXLE ASSY. 1
2 2CR-17121-70 GEAR, 2ND PINION 1
3 2CR-17131-70 GEAR, 3RD PINION 1
4 2CR-17151-70 GEAR, 5TH PINION 1
5 2CR-17161-70 GEAR, 6TH PINION A 1
6 2CR-17161-80 GEAR, 6TH PINION B 1
* 7 2CR-17402-00 DRIVE AXLE ASSY. 1
8 2CR-17211-70 GEAR, 1ST WHEEL 1
9 2CR-17221-70 GEAR, 2ND WHEEL 1
10 2CR-17231-70 GEAR, 3RD WHEEL 1
11 2CR-17241-70 GEAR, 4TH WHEEL 1
12 2CR-17251-70 GEAR, 5TH WHEEL 1
13 2CR-17261-70 GEAR 6TH WHEEL A 1
14 2CR-17261-80 GEAR 6TH WHEEL B 1

– 36 –
 8

12

10

13 14 11

4
1
3

5 6

NOTICE
This set contains modified gear ratios and
docks compared with the STD gearbox.
Kit gears cannot use combine standard
gear.

Gear ratio
STD KIT
1st 39/15 (2.600) 39/16 (2.438)
2nd 37/17 (2.176) 35/17 (2.059)
3rd 35/19 (1.842) 34/19 (1.789)
4th 30/19 (1.579) 33/21 (1.571)
5th 29/21 (1.381) 32/22 (1.455)
6th(A) 30/24 (1.250) 30/22 (1.364)
6th(B) 30/24 (1.250) 33/25(1.320)

– 37 –
 YZF-R1 Speed List
Engine speed (rpm) 13900
Primary reduction ratio 1.63
Tire diameter (mm) 642

The number of teeth 16 16 16 15 16 15 16 15 16 14 15 16 14 15 16 14 15 16

GEAR PLAN Ratio
P W 38 39 40 38 41 39 42 40 43 38 41 44 39 42 45 40 43 46
STD 15 39 2.60 166.6 162.3 158.3 156.2 154.4 152.2 150.7 148.4 147.2 145.8 144.8 143.9 142.0 141.3 140.7 138.5 138.0 137.6
1st
KIT 16 39 2.44 177.7 173.2 168.8 166.6 164.7 162.3 160.8 158.3 157.1 155.5 154.4 153.5 151.5 150.7 150.1 147.7 147.2 146.8
STD 17 37 2.18 199.0 193.9 189.1 186.6 184.5 181.8 180.1 177.3 175.9 174.2 172.9 171.9 169.7 168.8 168.1 165.4 164.9 164.4
2nd
KIT 17 35 2.06 210.4 205.0 199.9 197.3 195.0 192.2 190.4 187.4 185.9 184.1 182.8 181.7 179.4 178.5 177.7 174.9 174.3 173.8
STD 19 35 1.84 235.2 229.1 223.4 220.5 218.0 214.8 212.8 209.4 207.8 205.8 204.3 203.1 200.5 199.5 198.6 195.5 194.8 194.3
3rd
KIT 19 34 1.79 242.1 235.9 230.0 226.9 224.4 221.1 219.0 215.6 213.9 211.8 210.3 209.1 206.4 205.3 204.4 201.2 200.6 200.0
STD 19 30 1.58 274.4 267.3 260.6 257.2 254.3 250.6 248.2 244.3 242.5 240.1 238.4 236.9 233.9 232.7 231.7 228.1 227.3 226.6
4th
KIT 21 33 1.57 275.7 268.6 261.9 258.4 255.5 251.8 249.4 245.5 243.6 241.2 239.5 238.1 235.0 233.8 232.8 229.1 228.4 227.7
STD 21 29 1.38 313.7 305.6 298.0 294.1 290.7 286.5 283.8 279.4 277.2 274.5 272.6 270.9 267.4 266.1 264.9 260.8 259.9 259.1
5th
KIT 22 32 1.45 297.8 290.2 282.9 279.2 276.0 272.0 269.5 265.2 263.2 260.6 258.8 257.2 253.9 252.6 251.5 247.6 246.7 246.0
STD 24 30 1.25 346.6 337.7 329.2 324.9 321.2 316.6 313.5 308.6 306.3 303.2 301.1 299.3 295.5 293.9 292.6 288.1 287.1 286.3
6th KIT(A) 22 30 1.36 317.7 309.5 301.8 297.8 294.4 290.2 287.4 282.9 280.7 278.0 276.0 274.4 270.8 269.5 268.3 264.1 263.2 262.4

– 38 –
KIT(B) 25 33 1.32 328.2 319.8 311.8 307.7 304.2 299.8 296.9 292.3 290.0 287.2 285.1 283.4 279.8 278.4 277.1 272.8 271.9 271.1

The number of teeth 14 15 16 16 15 14 16 15 14 15 14 15 14 15 14 14 14 14

GEAR PLAN Ratio
P W 41 44 47 48 45 42 49 46 43 47 44 48 45 49 46 47 48 49
STD 15 39 2.60 135.1 134.9 134.7 131.9 131.9 131.9 129.2 129.0 128.8 126.3 125.9 123.7 123.1 121.1 120.4 117.9 115.4 113.1
1st
KIT 16 39 2.44 144.1 143.9 143.7 140.7 140.7 140.7 137.8 137.6 137.4 134.7 134.3 131.9 131.3 129.2 128.5 125.7 123.1 120.6
STD 17 37 2.18 161.4 161.1 160.9 157.6 157.6 157.6 154.4 154.1 153.9 150.9 150.4 147.7 147.1 144.7 143.9 140.8 137.9 135.1
2nd
KIT 17 35 2.06 170.6 170.4 170.1 166.6 166.6 166.6 163.2 162.9 162.7 159.5 159.0 156.2 155.5 153.0 152.1 148.9 145.7 142.8
STD 19 35 1.84 190.7 190.4 190.1 186.2 186.2 186.2 182.4 182.1 181.8 178.2 177.7 174.5 173.8 171.0 170.0 166.4 162.9 159.6
3rd
KIT 19 34 1.79 196.3 196.0 195.7 191.6 191.6 191.6 187.7 187.5 187.2 183.5 182.9 179.7 178.9 176.0 175.0 171.3 167.7 164.3
STD 19 30 1.58 222.5 222.1 221.8 217.2 217.2 217.2 212.8 212.5 212.1 208.0 207.3 203.6 202.7 199.5 198.3 194.1 190.0 186.2
4th
KIT 21 33 1.57 223.6 223.2 222.9 218.2 218.2 218.2 213.8 213.5 213.2 208.9 208.3 204.6 203.7 200.4 199.3 195.0 191.0 187.1
STD 21 29 1.38 254.4 254.0 253.6 248.3 248.3 248.3 243.3 242.9 242.6 237.8 237.0 232.8 231.8 228.1 226.7 221.9 217.3 212.9
5th
KIT 22 32 1.45 241.5 241.1 240.8 235.8 235.8 235.8 231.0 230.6 230.3 225.7 225.1 221.0 220.1 216.5 215.3 210.7 206.3 202.1
STD 24 30 1.25 281.0 280.6 280.2 274.4 274.4 274.4 268.8 268.4 268.0 262.7 261.9 257.2 256.1 252.0 250.5 245.2 240.1 235.2
6th KIT(A) 22 30 1.36 257.6 257.2 256.8 251.5 251.5 251.5 246.4 246.0 245.6 240.8 240.1 235.8 234.7 231.0 229.6 224.7 220.1 215.6
KIT(B) 25 33 1.32 266.1 265.7 265.3 259.8 259.8 259.8 254.5 254.2 253.8 248.7 248.0 243.6 242.5 238.6 237.2 232.2 227.3 222.7
17. Mission Maintenance Set (2CR-A7000-70)

Parts List
No. PART No. PART NAME Q'TY REMARKS
* 21 90387-28003 COLLAR 3
* 22 90209-25011 WASHER 6
* 23 93440-28184 CIRCLIP 6
* 24 90387-25023 COLLAR 3
* 25 90214-25004 WASHER, CLAW 3
* 26 90214-25003 WASHER, CLAW 3
* 27 90387-31003 COLLAR 3
* 28 90209-28008 WASHER 9
* 29 93440-31187 CIRCLIP 9
* 30 90387-28004 COLLAR 6
* 31 90214-29002 WASHER, CLAW 3
* 32 90214-28002 WASHER, CLAW 3
* 33 90387-25008 COLLAR 3
* 34 93102-40330 SEAL, OIL 3
* 35 93440-62032 CIRCLIP 3
* 36 90201-257H0 WASHER, PLAIN 3
* 37 93306-27214 BRG. 3
38 5VY-17166-00 BRG., 2 3

This kit contains three (3) sets of par ts

necessary for transmission disassembly and
maintenance.

– 39 –
38

36

33

29
28

30 32
31
29
28 30
28
29
27

34

35

21

22
23

23
22
24
25
26

37

– 40 –
Transmission Assembly

The seal side should face outward A M1

B M3
B M1
(one side seal bearing) and press M1
in the bearing cup all the way into
the case until it touches bottom.

Apply molybdenum oil to inside of diameter.

M1 After assembly, it should rotate smoothly.
Apply molybdenum oil to the inside diameter
M2 and end. After assembly, it should rotate
smoothly.
Apply molybdenum oil to teeth of spline.
M3 After assembly, it should slide smoothly.

The seal side should face outward (one

Points to be careful of the oil seal assembly side seal bearing) and assembled toward
The convex part on the oil seal should be the case right side edge.
put into the case groove vertically so that
the oil seal does not fall over and is tightly M2 M3 M2 M3 M2
fit into the bearing cup of the bearing. B B C B
(Apply grease to the lip.)

TIP
• Always use a new circlip.
• Do not mistake the washer and circlip directions.
(See drawing below.)
Matching mark
Matching mark

Washer
Circlip Washer
Washer

Gear
Shaft Install the circlip with its inner
diameter R portion to the gear
side and its edge portion to the
Shaft Edge PortionR opposite side.
Edge Portion R
Position the center of the abutment joint
of the circlip right with the spline threads.

Detail of installation of washer

Rotate washer so that its teeth meet axle-
spline teeth on the axle, and then lock with
,
washer s claw.
Assemble washer with putting together
their matching mark.
Detail of installation of circlip
Matching mark
Matching mark
Washer

Washer

Shaft
Edge Portion R

Detail of installation of washer

– 41 –
18. Drive Sprockets

Parts List
No. PART No. PART NAME Q'TY REMARKS
1 2CR-17460-74 SPROCKET, DRIVE 1 14T, 520SIZE
2 2CR-17460-75 SPROCKET, DRIVE 1 15T, 520SIZE
3 2CR-17460-76 SPROCKET, DRIVE 1 16T, 520SIZE

This sprocket is weight-saved by changing the

chain size to 520 in relation to the STD one.

– 42 –
19. Sprocket Nut Set (2CR-A7463-70)

Parts List
No. PART No. PART NAME Q'TY REMARKS
* 1 90179-22018 NUT 3
* 2 90208-22002 WASHER, CONICAL SPRG. 3

Apply swage after tightening a nut

The “OUT” mark must face outward

– 43 –
20. Strainer Cover Set (2CR-13400-71)

Parts List
No. PART No. PART NAME Q'TY REMARKS
○ 1 2CR-13410-71 STRAINER [Link]. 1
○ 2 2CR-13576-70 SPACER 1
* 3 93210-22M93 O-RING 2 2 attachment, Grease outer surface
* 4 92017-06014 BOLT,BUTTON HEAD 2 2 attachment
* 5 90110-06172 BOLT, HEX. SOCKET 2 1 attachment
○ 6 2CR-13418-70 PIPE,OIL 2 1
○ 7 2CR-13416-71 PIPE,OIL 1 1
* 8 93210-14003 O-RING 3 6, 7 attachment, Grease outer surface
* 9 90110-06393 BOLT,HEX. SOCKET 1 6 attachment
* 10 90110-06182 BOLT,HEX. SOCKET 1 7,23 attachment
○ 11 2CR-13161-70 PIPE,DELIVERY 1 1
* 12 90480-13010 GROMMET 1 1,11,23 attachment
* 13 5VY-13117-10 COLLAR,DISTANCE 1 1,11,23 attachment
* 14 90109-06015 BOLT 1 1,11,23 attachment
○ 15 2CR-1310A-70 PAN,OIL 1 The number of the oil window
changed:
2 ('16 kit) → 1 ('17~ kit)
16 0NC0-90100-00 BOLT 12 15 attachment M6×1.0×L25
* 17 90340-14019 PLUG,STRAIGHT SCREW 1
* 18 90430-14005 GASKET 1
○ 19 2CR-13414-70 GASKET, STRAINER 1 1 attachment
○ 20 2CR-13317-70 BAFFLE, PLATE 1
21 90119-06115 BOLT 4 20 attachment
22 90201-09M01 WASHER,PLAIN 1 1,11,23 attachment
○ 23 2CR-13428-70 BRKT.,STRAINER 1 1 1,11 attachment
The tightening torque of this set is same as
that of STD.
Use the screw locking solvent and grease
same as STD.
For details, refer to the STD service manual
published by Yamaha Motor Co.,Ltd.

For details on installation of this set, see the

next page.

Meaning of the symbol marks in the figures

LT : Apply LOCTITE 620

620

: Tighten based on the specified tightening

torque
– 44 –
Installation
1. Put (8) O-RING at (7) PIPE,OIL 1, and connect
(6) PIPE,OIL 2 to (7 )PIPE,OIL 1.
2. Attach (6) PIPE,OIL 2 to the engine by using (8)
O-RING and (9) BOLT,HEX. SOCKET.
3. Attach (7)PIPE,OIL 1 and (23)BRKT.,STRAINER
1 to the engine by using(8)O-RING and(10)
BOLT,HEX. SOCKET (tighten (7) PIPE,OIL 1
together with (23) BRKT.,STRAINER 1).

7
6 23

3 4

TIP

Visually confirm the condition of 6 PIPE,OIL 2

and 7 PIPE,OIL 1 periodically.

4. Attach (11)PIPE, DELIVERY 1 to the engine.

5. Fix (1) STRAINER [Link]. to the engine
by using (5)BOLT,HEX. SOCKET and (19
GASKET, STRAINER.

11

19
– 45 –
6. Fix (1) STRAINER [Link]., 11 PIPE,
DELIVERY 1 and (23)BRKT.,STRAINER
1 b y u s i n g ( 1 2 ) G R O M M E T, ( 1 3 )
COLLAR,DISTANCE, (14) BOLT and (22)
WASHER,PLAIN.

11 1

23

1
14

22
11

12

13

23

7. A t t ac h (2 0) B A FFL E, PL AT E to (15 )
PAN,OIL by using 21 BOLT.

21

21
LT

620
21

20
15
– 46 –
8. Attach (15) PAN,OIL to the engine by
using (16)BOLT,BUTTON HEAD.

15

TIP

Be sure to check the torque when

installing.

9. Attach (17)PLUG,STRAIGHT SCREW

and (18 )GASKET to (15)PAN,OIL.

17
18

– 47 –
Recommended oil level
After engine warm-up (water temperature of
75 to 80 degrees), while using the racing (rear)
stand, and check that the oil level is within a
range of the upper limit of the oil pan window
(right side of the vehicle) to the lower limit of
the engine crank case oil window (left side of
vehicle).
If it is out of range, adjust the oil level.

<Oil pan window (right side of vehicle)>

<Engine crank case oil window (left side of vehicle)>

– 48 –
2-3 Installing Chassis Parts
21. Spring Rear Shock

Parts List
No. PART No. PART NAME Q'TY REMARKS
1 2CR-22222-A0 SPRG., REAR SHOCK 1 83 N/mm
Identifying stamp:
159.5-56-83
2 2CR-22222-70 SPRG., REAR SHOCK 1 93 N/mm
Identifying stamp:
159.5-56-93
3 2CR-22222-75 SPRG., REAR SHOCK 1 98 N/mm
Identifying stamp:
159.5-56-98
4 2CR-22222-80 SPRG., REAR SHOCK 1 103 N/mm
Identifying stamp:
159.5-56-103
5 2CR-22222-85 SPRG., REAR SHOCK 1 108 N/mm
Identifying stamp:
159.5-56-108

• There is a stamp on the side of the springs

for rate identification.
• Free length is 159.5 mm for the both STD
spring and KIT spring.
• For spring replacement, see the 2CR STD.
Service Manual.
• The spring rate of the standard rear
suspension is 88 N/mm.

– 49 –
22. Spring Front Fork

Parts List
No. PART No. PART NAME Q'TY REMARKS
1 2CR-23141-A0 SPRG., FRONT FORK 1 8.5 N/mm
Identifying slits 1-1
2 2CR-23141-70 SPRG., FRONT FORK 1 9.0 N/mm
Identifying slits 1
3 2CR-23141-75 SPRG., FRONT FORK 1 9.5 N/mm
Identifying slits 2
4 2CR-23141-80 SPRG., FRONT FORK 1 10.0 N/mm
Identifying slits 3
5 2CR-23141-85 SPRG., FRONT FORK 1 10.5 N/mm
Identifying slits 4

• There are slits at the ends of the spring • For information about spring replacement,
for rate identification. see 2CR STD. Service Manual.
• The spring rate of the STD is 9.0 N/mm.

-A0 -70
8.5 N/mm 9.0 N/mm

-75 -80
9.5 N/mm 10.0 N/mm

-85
10.5 N/mm

• There are slits at the ends of the spring

for rate identification.

• Use the preload tube of the STD for

installing the KIT spring.
• Free lengths are STD spring = 217.5mm
and KIT spring = 215 mm.
STD :Preload adjuster 0 mm = Actual
preload 2.5 mm
KIT :Preload adjuster 0 mm = Actual
preload 0 mm
– 50 –
References
Front and rear load changes and front and rear suspension movement
in different scenarios.

Accelerating
. Load change
The wider the throttle is opened, the more the load
is concentrated on the rear.
. Front fork
Reaches nearly maximum extended stroke.
. Rear cushion
Up to 20 to 30mm stroke displacement, depending
on conditions.

Braking
. Load change
The harder the brake is applied, the more the load
is concentrated on the front.
. Front fork
Displaces until stroke has almost bottomed.
. Rear cushion
Reaches nearly maximum extended stroke.

Cornering
. Load change
Increases the load on the front fork and rear
cushion on both sides.
. Front fork
Up to 30 to 90mm stroke displacement depending
on the size of the corner.
. Rear cushion
Up to 25 to 40mm stroke displacement, depend-
ing on conditions.

– 51 –
23. Seat Cushion (13S-24713-70)

Parts List

No. PART No. PART NAME Q'TY REMARKS

1 13S-24713-70 CUSHION SEAT 1

Anti slip seat.

Cut to any size for use.

– 52 –
24. Front Spare Wheel ASS’Y (2CR-25100-70)

Parts List
No. PART No. PART NAME Q'TY REMARKS
1 2CR-25160-00 CAST WHEEL ASSY. 1
* 2 93900-00030 VALVE, RIM 1
* 3 1SD-2517G-00 ROTOR, SENSOR 1
* 4 2CR-2514A-00 RING, WHEEL 1 1
* 5 90149-05037 SCREW 5
* 6 93210-47440 O-RING 1

*This kit does not include a tire.

This part is the STD wheel, bearing, spacer,

air valve and center rotor combined.

– 53 –
25. Rear Spare Wheel ASS’Y (2CR-25300-70)

Parts List
No. PART No. PART NAME Q'TY REMARKS
1 2CR-25370-00 CAST WHEEL ASSY. 1
2 2CR-25840-00 DISK BRAKE ASSY. 1
* 3 90111-08085 BOLT, HEX. SOCKET 5
BUTTON
* 4 93900-00030 VALVE, RIM 1

*This kit does not include a tire.

This part is the STD wheel, bearing, spacer,

air valve, rear disk brake and center rotor
combined.

– 54 –
26. Tube Guide (2CR-26243-70)

Parts List
No. PART No. PART NAME Q'TY REMARKS
1 2CR-26243-70 TUBE, GUIDE 1

About the Throttle Tube Guide Specifications

As shown below, the operating angle of the
throttle grip when the throttle is fully opened is
57.5° as against STD 64.4°.
(Except this part, all other parts (such as a
throttle wire) should be STD parts)

Throttle body opening ’15 KIT specification

Fully opened

5SL-71

STD

Fully closed
53.5˚
57.5˚

64.4˚

Throttle grip operation angle (°)

Installation
1. Replace the STD tube guide with the KIT 2. As shown below, cut off the stopper inside
tube guide. the pull side cap grip.

D
FW

– 55 –
3 Tightening Torque List
Engine

To be tightened Part No. Part Name Thread dia. Tightening Q’ty Remarks
x torque N•m
pitch (kgf•m)
Plug for sand 90340-18004 PLUG, M18 × 1.5 25 ± 2 2 APPLY LOCKING
drain hole STRAIGHT (2.5 ± 0.2) AGENT
SCREW (LOCKTITE®
TO BOTH
SCREW
THREAD AND
TAPERED
PORTION.

Install SPARK 94700-00424 PLUG, M10S × 12 – 15 4 FOR DETAILS,

PLUG SPARK 1.0 (1.2 – 1.5) SEE page 26.

Tighten HEAD 90119-09016 BOLT, M9 × 1.25 TURN OF NUT 10 FOR DETAILS,

HEXAGON METHOD: AXIAL SEE page 69.
WITH FORCE TARGET
WASHER VALUE OF
40kN ± 2kN

Tighten HEAD 90110-06315 BOLT, M6 × 1.0 12±2 2

HEXAGON (1.2±0.2)
SOCKET
HEAD

CAP x HEAD 90105-06027 BOLT, M6 x 1.0 [When using the bolt 10

FLANGE continuously]
Apply oil to the
bearing surface and
thread part of the
bolt, and tighten with
tightening torque
8.0±1.0 N•m (0.8±0.1
kgf•m).
[When replacing with
a new bolt]
CAP x HEAD 90105-06209 BOLT, M6 x 1.0 Tighten with 10
FLANGE tightening torque
10.0±2.0 N•m
(1.0±0.2 kgf•m).
It is not necessary
to apply oil to the
bearing surface and
thread part of the bolt
Use it in the delivery
condition (corrosion-
proof oil is applied).

Tighten HEAD 5VY-1119E-00 BOLT, COV- M6 x 1.0 10±2 6

COVER ER HEAD (1.0±0.2)

Embedded in 95612-08615 BOLT, M8 x 1.25 15±3 8

HEAD STUD (1.5±0.3)

(Install [Link])

AI CAP 90110-06175 BOLT, M6 x 1.0 10±2 4 APPLY TO SCREW

HEXAGON (1.0±0.2) ROCKING
SOCKET
HEAD

– 56 –
Engine

To be tightened Part No. Part Name Thread dia. Tightening Q’ty Remarks
x torque N•m
pitch (kgf•m)
HEAD x JOINT, 90110-06168 BOLT, M6 x 1.0 10±2 6 APPLY TO SCREW
ASSY HEXAGON (1.0±0.2) ROCKING
SOCKET
HEAD

ROCKER AXIS 90340-12013 PLUG, M12 x 1.0 10±2 3 APPLY TO SCREW

PLUG STRAIGHT (1.0±0.2) ROCKING
SCREW

ROCKER AXIS 90109-05015 BOLT M5 x 0.8 6±1 4 APPLY TO SCREW

FIXING PIN (6.0±0.1) ROCKING

CON ROD 2CR-11654-00 BOLT, M9 x 0.75 [Link] oil from 8 * Do not leave EG
CON-ROD the bearing surface each oil or grease on
BIG END and female thread the bearing sur-
part of the con rod, face or thread
and dry them for part of the bolt.
more than 5 min- * Do not apply/
utes. remove oil to/
[Link] an F-shaped from the bolt.
torque wrench to
tighten with initial In case you have
tightening torque applied/remove
25.0±2.0 N•m to/from the bolt,
(2.5±0.2 kgf•m). replace it with
[Link] additional new one.
tightening with
angle 180±5°. Use a new bolt
[Link] that the final only. Do not re-
tightening torque is use the bolt.
40.0 to 85.0 N•m
(4.0 to 8.5 kgf•m).

If not, replace the

bolt with new one
and re-tight it again.

ACM rotor 90109-10061 BOLT M10 x 85±5 1 Remove oil from

1.25 (8.5±0.5) the taper surface.
Apply oil to the
bearing surface
and thread part of
the bolt, and the
both sides of the
washer.

SPROCKET, 2CR-12157-00 BOLT M12 x 72±5 1 Apply oil to the

CRANK 1.25 (7.2±0.5) bearing surface
and thread part of
the bolt.

CAM CHAIN, 90110-06178 BOLT, M6 x 1.0 10±2 2 APPLY TO SCREW

TENSIONER HEXAGON (1.0±0.2) ROCKING
SOCKET
HEAD

Install PIPE 1, 4 90110-06246 BOLT, M6 x 1.0 10±2 1 APPLY TO SCREW

(Water pump) HEXAGON (1.0±0.2) ROCKING.
SOCKET WATER PUMP
HEAD SIDE

– 57 –
Engine

To be tightened Part No. Part Name Thread dia. Tightening Q’ty Remarks
x torque N•m
pitch (kgf•m)
Install THERMO- 90110-06163 BOLT, M6 x 1.0 10±2 2 The rear of the
STAT ASSY. HEXAGON (1.0±0.2) head cylinder
SOCKET
HEAD

Install PIPE 1 90105-06127 BOLT, M6 x 1.0 10±2 4

(Body cylinder, FLANGE (1.0±0.2)

case)

PIPE 4 (Case) 91312-06014 BOLT, M6 x 1.0 10±2 1

HEXAGON (1.0±0.2)
SOCKET
HEAD

Install PUMP 91314-06035 BOLT, M6 x 1.0 10±2 2

HEXAGON (1.0±0.2)
SOCKET
HEAD

THERMOSTAT 90176-06017 CAP, NUT M6 x 1.0 10±2 2

ASSY (1.0±0.2)

Install OIL PUMP 95817-06035 BOLT, M6 x 1.0 10±2 2

ASSY. FLANGE (1.0±0.2)
95817-06025 BOLT, M6 x 1.0 10±2 1
FLANGE (1.0±0.2)

Tighten DRAIN 90340-14019 PLUG, M14 x 1.5 23±2 1

BOLT STRAIGHT (4.3±0.4)
SCREW

Install PIPE, 90110-06182 BOLT, M6 x 1.0 10±2 2 APPLY TO SCREW

OIL 1 HEXAGON (1.0±0.2) ROCKING
SOCKET
HEAD

Install 90110-06173 BOLT, M6 x 1.0 10±2 3 APPLY TO SCREW

HOUSING, HEXAGON (1.0±0.2) ROCKING
SOCKET
STRAINER HEAD

Install RELIEF 90110-06169 BOLT, M6 x 1.0 10±2 2 APPLY TO SCREW

VALVE HEXAGON (1.0±0.2) ROCKING
SOCKET
HEAD

Install PIPE 90110-06182 BOLT, M6 x 1.0 10±2 2 APPLY TO SCREW

HOLDER HEXAGON (1.0±0.2) ROCKING
SOCKET
HEAD

Install oil 90110-06182 BOLT, M6 x 1.0 10±2 2 APPLY TO SCREW

delivery pipe 2 HEXAGON (1.0±0.2) ROCKING
SOCKET
HEAD

Install oil 90149-06158 SCREW M6 x 1.0 10±2 1 APPLY TO SCREW

delivery pipe 5 (1.0±0.2) ROCKING

Tighten 90401-20008 BOLT, M20 x 1.5 70±10 1 Apply oil when

CLEANING UNION (7.0±1.0) tightening the
case.
BOLT, UNION
– 58 –
Engine

To be tightened Part No. Part Name Thread dia. Tightening Q’ty Remarks
x torque N•m
pitch (kgf•m)
Install OIL 5GH-13440-60 OIL M20 x 1.5 17±2 1 APPLY
CLEANER CLEANER (1.7±0.2) GREASE
ASSY TO O-RING.
ASSY

Install OIL PAN 90111-06168 BOLT, M6 x 1.0 10±2 2 APPLY TO SCREW

BAFFLE HEXAGON (1.0±0.2) ROCKING
SOCKET
HEAD

Install COVER, 90109-06300 BOLT M6 x 1.0 FOR DETAILS, 12 STRAINER

STRAINER SEE page 71. COVER
(List of tightening AL
bolts)

Tighten the main 90110-06395 BOLT, M6 x 1.0 10±2 1 APPLY TO SCREW

gallery side of HEXAGON (1.0±0.2) ROCKING
SOCKET
OIL PIPE COMP. HEAD

Tighten together 90110-06389 BOLT, M6 x 1.0 10±2 2 APPLY TO SCREW

with OIL PIPE HEXAGON (1.0±0.2) ROCKING
SOCKET
COMP. HEAD

Tighten the cover 90110-06295 BOLT, M6 x 1.0 10±2 1 APPLY TO SCREW

side of OIL PIPE HEXAGON (1.0±0.2) ROCKING
SOCKET
COMP.2 HEAD

Install OIL HOSE 90110-06211 BOLT, M6 x 1.0 10±2 4 APPLY TO SCREW

HEXAGON (1.0±0.2) ROCKING
SOCKET
HEAD

Install OIL 90110-06341 BOLT, M6 x 1.0 10±2 3

COOLER STAY HEXAGON (1.0±0.2)
SOCKET
HEAD

Install the upper 90110-06346 BOLT, M6 x 1.0 10±2 2

side of the OIL HEXAGON (1.0±0.2)
SOCKET
COOLER HEAD

Install the lower 95827-06030 BOLT, M6 x 1.0 10±2 1

of the OIL FLANGE (1.0±0.2)

COOLER

Install 2CR-26302-00 BOLT, M6 3.5 – 5.5 2

THROTTLE ADJUSTING (0.35 – 0.55)

WIRE

JOINT ASSY x 90450-60004 HOSE M5 x 0.8 3±0.5 4 Collar striking or

THROTTLE CLAMP (0.3±0.05) torque manage-
ment
BODY

THROTTLE x 90110-06163 BOLT M6 x 1.0 8±2 6

FUNNEL (0.8±0.2)

– 59 –
Engine

To be tightened Part No. Part Name Thread dia. Tightening Q’ty Remarks
x torque N•m
pitch (kgf•m)
UPPER 98907-05020 SCREW, M5 x 0.8 2.0±0.5 10 (TARGET
COVER BINDING (0.2±0.05) VALUE OF
HEAD 2.0 N•m)

NUT, RING x 90179-08442 NUT M8 x 1.25 20±2 8

CYLINDER (2.0±0.2)

HEAD

EX. PIPE x 95024-08035 BOLT, M8 x 1.25 20±2 2

CHAMBER FLANGE (2.0±0.2)
(SMALL
HEAD)

CHAMBER x 90109-08238 BOLT M8 x 1.25 20±2 2

STAY MUFFLER (2.0±0.2)

CHAMBER x 90110-08099 BOLT, M8 x 1.25 20±2 1

SIDE STAND HEXAGON (2.0±0.2)
SOCKET

CHAMBER x 90110-06343 BOLT, M6 x 1.0 10±2 1

SILENCER HEXAGON (1.0±0.2)
SOCKET

SILENCER x 90110-08071 BOLT, M8 x 1.25 20±2 1

STAY HEXAGON (2.0±0.2)
SOCKET
MUFFLER3

Install WIRE 2CR-1133E-oo WIRE, M6 x 1.0 5–7 2

PULLEY PULLEY,1 (0.5 – 0.7)

DOUBLE NUT 2CR-1133F-oo WIRE,

PULLEY,2

Install 90110-06106 BOLT, M6 x 1.0 10±2 1

SERVOMOTOR HEXAGON (1.0±0.2)
SOCKET

CHAMBER x 90111-06153 BOLT, M6 x 1.0 10±2 3

PROTECTOR HEXAGON (1.0±0.2)
SOCKET
ASSY. BUTTON

OIL PATHWAY 2CR-15138-00 NOZZLE M8 x 1.25 2.5 – 3.5 5 Control by ad-

THROTTLING (0.25 – 0.35) ditional tightening
method
NOZZLE

CRANKCASE 1 90119-09010 BOLT, M9 x 1.25 FOR DETAILS, 10 Apply oil to the

x CRANKCASE 2 HEXAGON SEE page 70. thread part and
WITH (Installing the Crank- bearing surface.
WASHER case) Do not reuse a
mended part.

CRANKCASE 1 14B-15156-00 BOLT, M8 x 1.25 24±2 8 Apply oil to the

x CRANKCASE 2 CRANK- (2.4±0.2) thread part, bear-
CASE ing surface and
JOURNAL O-RING part.
Do not reuse a
mended O-RING.

– 60 –
Engine

To be tightened Part No. Part Name Thread dia. Tightening Q’ty Remarks
x torque N•m
pitch (kgf•m)
CRANKCASE 1 95812-08060 BOLT, M8 x 1.25 24±2 2 APPLY OIL TO
x CRANKCASE 2 FLANGE (2.4±0.2) BOTH SCREW
THREAD AND
BEARING.

CRANKCASE 1 90109-06100 BOLT M6 x 1.0 10±2 2 APPLY OIL TO

x CRANKCASE 2 (1.0±0.2) BOTH SCREW
THREAD AND
BEARING.

CRANKCASE 1 95812-06070 BOLT, M6 x 1.0 10±2 1 APPLY OIL TO

x CRANKCASE 2 FLANGE (1.0±0.2) BOTH SCREW
THREAD AND
BEARING.

CRANKCASE 1 95812-06060 BOLT, M6 x 1.0 10±2 6 APPLY OIL TO

x CRANKCASE 2 FLANGE (1.0±0.2) BOTH SCREW
THREAD AND
BEARING.

CRANKCASE 1 95812-06050 BOLT, M6 x 1.0 10±2 4 APPLY OIL TO

x CRANKCASE 2 FLANGE (1.0±0.2) BOTH SCREW
THREAD AND
BEARING.

CRANKCASE 1 90105-06213 BOLT M6 x 1.0 10±2 2 APPLY TO SCREW

x CRANKCASE 2 (1.0±0.2) ROCKING.
APPLY OIL TO
THE BEARING
SURFACE ONLY.

CRANKCASE 1 95812-06040 BOLT, M6 x 1.0 10±2 5 APPLY OIL TO

x CRANKCASE 2 FLANGE (1.0±0.2) BOTH SCREW
THREAD AND
BEARING.

Install NOZZLE 90149-06158 SCREW M6 x 1.0 10±2 4 APPLY TO SCREW

ASSY. (1.0±0.2) ROCKING

(15105)

Install COVER 90109-06300 BOLT M6 x 1.0 FOR DETAILS, 8 ACM COVER

CRANK CASE 1 SEE page 71.
(List of tightening AL
(15411) bolts)

Install COVER 90110-06387 BOLT, M6 x 1.0 10±2 3 DRIVE

CHAIN CASE HEXAGON (1.0±0.2) SPROCKET
SOCKET COVER
(15418) HEAD

Install COVER 90109-06301 BOLT M6 x 1.0 FOR DETAILS, 10 CLUTCH

CRANK CASE 2 SEE page 71. COVER
(List of tightening AL
(15421) bolts)

Install COVER 1 90109-06299 BOLT M6 x 1.0 FOR DETAILS, 5 CAM CHAIN

(15416) SEE page 71. COVER
(List of tightening AL
bolts)

Install COVER 90109-06300 BOLT M6 x 1.0 FOR DETAILS, 8 BREATHER

(15413) SEE page 71. COVER
(List of tightening AL
bolts)

– 61 –
Engine

To be tightened Part No. Part Name Thread dia. Tightening Q’ty Remarks
x torque N•m
pitch (kgf•m)
Install PLATE, 90149-06158 SCREW M6 x 1.0 10±2 4 APPLY TO SCREW
BREATHER (1.0±0.2) ROCKING

Install PLUG to 90340-27003 PLUG, M27 x 1.5 15±2 1 FOR CRANK

COVER CRANK STRAIGHT (1.5±0.2) ROTATION
SCREW
CASE 1

Install COVER 90109-08239 BOLT M8 x 1.25 15±2 1 CHECK TIMING.

CRANK CASE 1 (1.5±0.2)

Install PLUG to 2CR-15363-01 PLUG, OIL M20 x 1.5 Attached firmly to the 1
COVER CRANK bearing surface.

CASE 2

Install DAMPER to 90149-06158 SCREW M6 x 1.0 10±2 4 APPLY TO SCREW

COVER CRANK (1.0±0.2) ROCKING

CASE 2

PLUG for REAR 4H7-15189-00 PLUG M20 x 1.5 8±2 2 TAKE CARE
PATHWAY of OIL (0.8±0.2) NOT TO
OVERTIGHTEN.
FILTER

Install CLUTCH 90110-06340 BOLT M6 x 1.0 10±2 2 APPLY TO SCREW

WIRE HOLDER (1.0±0.2) ROCKING

ACM LEAD 90110-06182 BOLT, M6 x 1.0 10±2 1 APPLY TO SCREW

HEXAGON (1.0±0.2) ROCKING
SOCKET
HEAD

Install STATOR 90149-06128 SCREW M6 x 1.0 10±2 3 APPLY TO SCREW

(1.0±0.2) ROCKING.
TORQUES

Install PLUG 90110-06396 BOLT, M6 x 1.0 10±2 2

(2CR-15189-00-1) HEXAGON (1.0±0.2)
SOCKET

Install JOINT 90149-06068 SCREW M6 x 1.0 10±2 1 TAKE CARE

(15319) (1.0±0.2) NOT TO
OVERTIGHTEN.
FOR HYDRAU-
LIC SENSOR.

Install PLATE 90110-06108 BOLT, M6 x 1.0 12±2 4 APPLY TO SCREW

(15113) HEXAGON (1.2±0.2) ROCKING
SOCKET

Install IDLER 90110-06401 BOLT, M6 x 1.0 10±2 1 APPLY TO SCREW

SHAFT HEXAGON (1.0±0.2) ROCKING
SOCKET

Install STARTER 90149-06158 SCREW M6 x 1.0 14±2 3 APPLY TO SCREW

ONE-WAY (1.4±0.2) ROCKING

OUTER

– 62 –
Engine

To be tightened Part No. Part Name Thread dia. Tightening Q’ty Remarks
x torque N•m
pitch (kgf•m)
Install CLUTCH 90179-20007 NUT M20 x 1.0 125±5 1 APPLY OIL TO
BOSS (12.5±0.5) BOTH SCREW
THREAD AND
BEARING.
1 POINT SWAG-
ING AFTER
TIGHTENING

Install CLUTCH 2CR-16337-00 SCREW, M6 x 1.0 10±2 3

SPRING SPRING1 (1.0±0.2)

Install 90149-06082 SCREW M6 x 1.0 12±2 3 APPLY TO SCREW

BEARING (1.2±0.2) ROCKING

HOUSING

Tighten DRIVE 90179-22018 NUT M22x 1.0 125±10 1 2 POINT SWAG-

SPROCKET (12.5±1.0) ING AFTER
TIGHTENING

Install 90149-06158 SCREW M6 x 1.0 10±2 2 APPLY TO SCREW

STOPPER, (1.0±0.2) ROCKING

SHIFT BAR and

PLATE,
STOPPER 2

Install 1D7-18127-00 STOPPER, M8 x 1.25 22±2 1 APPLY TO SCREW

STOPPER SCREW (2.2±0.2) ROCKING

SCREW

Install ARM, 90105-06127 BOLT, M6 x 1.0 10±2 1 CHECK SERRA-

SHIFT FLANGE (1.0±0.2) TION FOR
TIGHTENING
UP

Install SENSOR, 90110-05067 BOLT, M5 x 0.8 3–5 2 APPLY TO SCREW

GEAR POSITION HEXAGON (0.3 – 0.5) ROCKING
SOCKET

Install 3GB-82540-01 NEUTRAL M10 x 17±3 1 OVERTIGHTEN-

NEUTRAL SWITCH 1.25 (1.7±0.3) ING MAY DAM-
ASSY. AGE THE PART
SWITCH

Install COVER, 97702-50514 SCREW, M5 1–3 2

SERVOMOTOR TRUSS (0.1 – 0.3)
HEAD TAP-
PING

Install THERMO 4P9-83591-00 THERMO M10 x 16±2 1

SENSOR SENSOR 1.25 (1.6±0.2)
ASSY
(for water
temperature)

SENSOR, CAM 90110-06175 BOLT, M6 x 1.0 7.5±1.5 1 APPLY TO SCREW

POSITION HEXAGON (0.75±0.15) ROCKING
SOCKET
HEAD

– 63 –
Engine

To be tightened Part No. Part Name Thread dia. Tightening Q’ty Remarks
x torque N•m
pitch (kgf•m)
Install PICKUP 90110-05034 BOLT, M5 x 0.8 6±1 2 APPLY TO SCREW
ASSY HEXAGON (0.6±0.1) ROCKING
SOCKET
HEAD

OIL PRESSURE 1WS-82504-00 SW. OIL PT1/8 12.5±2 1 When mended, use
SWITCH PRESSURE (1.25±0.2) 67F-82504-00
and apply the
sealing agent to
the thread part
ThreeBond
MEC #2403

Install OIL PRES- WS-82504-00 BOLT M4 x 0.7 1.5 – 2.0 1

SURE SWITCH accessory (0.15 – 0.2)

LEAD WIRE

Install 91312-06030 BOLT, M6 x 1.0 10±2 2

STARTER HEXAGON (1.0±0.2)
SOCKET
MOTOR HEAD

BX4 SERIES

To be tightened Part No. Part Name Thread dia. Tightening Q’ty Remarks
x torque N•m
pitch (kgf•m)
Install COVER, BX4-13573-00 BOLT M6 x 1.0 FOR DETAILS, 2 STRAINER
STRAINER SEE page 71. COVER
(List of tightening AL
bolts)

Install COVER 90109-06301 BOLT M6 x 1.0 FOR DETAILS, 10 CLUTCH

CRANK CASE 2 SEE page 71. COVER
(List of tightening AL
(15421) bolts)

Install CLUTCH 90110-06399 BOLT M6 x 1.0 10±2 2 APPLY TO SCREW

WIRE HOLDER (1.0±0.2) ROCKING

– 64 –
Chassis

To be tightened Part No. Part Name Thread dia. Tightening Q’ty Remarks
x torque N•m
pitch (kgf•m)
E/G BRACKET, 90110-12007 BOLT, M12 x 1.25 64 – 76 1 PROCEDURE
FRONT, LEFT HEXAGON (6.4 – 7.6) TO INSTALL
SOCKET THE ENGINE.
FOR DETAILS,
SEE page 73.

E/G BRACKET, 90111-12003 BOLT, M12 x 1.25 64 – 76 1 PROCEDURE

FRONT, RIGHT HEXAGON (6.4 – 7.6) TO INSTALL
SOCKET THE ENGINE.
BUTTON FOR DETAILS,
SEE page 73.

E/G BRACKET, 90110-12008 BOLT, M12 x 1.25 50 – 62 1 PROCEDURE

REAR UPPER HEXAGON (5.0 – 6.2) TO INSTALL
SOCKET THE ENGINE.
FOR DETAILS,
90179-12004 NUT SEE page 73.

E/G BRACKET, 90110-12010 BOLT, M12 x 1.25 50 – 62 1 PROCEDURE

REAR UNDER HEXAGON (5.0 – 6.2) TO INSTALL
SOCKET THE ENGINE.
FOR DETAILS,
90179-12004 NUT SEE page 73.

ADJUST BOLT 5YU-21495-00 BOLT, M18 x 1.0 7–9 2 PROCEDURE

for E/G ENGINE (0.7 – 0.9) TO INSTALL
ADJUSTING THE ENGINE..
BRACKET, FOR DETAILS,
REAR SEE page 73.
Apply grease or
engine oil (10W-
30 or 20W-40
equivalent) and
tighten it.
Be sure to
tighten at the nut
side.

STAY and M6 x 1.0 7 – 10 1

FRAME on the (0.7 – 1.0)

front side of the

tank

MAIN FRAME & 90149-10002 SCREW M10 x 1.25 33 – 40 4

REAR FRAME (3.3 – 4.0)

SHAFT, PIVOT 14B-22141-00 SHAFT, M30 x 1.0 5–8 1 PROCEDURE

& FRAME PIVOT (0.5 – 0.8) TO INSTALL THE
PIVOT SHAFT
PERIPHERAL
PARTS.
FOR DETAILS,
SEE page 74.

SHAFT, PIVOT 4C8-22252-00 NUT, 2 M30 x 1.0 50 – 80 1 PROCEDURE

& LOCK NUT (5.0 – 8.0) TO INSTALL THE
PIVOT SHAFT
PERIPHERAL
PARTS.
FOR DETAILS,
SEE page 74.

– 65 –
Chassis

To be tightened Part No. Part Name Thread dia. Tightening Q’ty Remarks
x torque N•m
pitch (kgf•m)
SHAFT, PIVOT 90185-20008 NUT, SELF M20 x 1.5 80 – 130 1 PROCEDURE
& U NUT LOCKING (8.0 – 13.0) TO INSTALL THE
PIVOT SHAFT
PERIPHERAL
PARTS.
FOR DETAILS,
SEE page 74.

ARM RELAY and 90109-10017 BOLT M10 x 1.25 31 – 49 1

FRAME (3.1 – 4.9)
95602-10200 NUT, U
FLANGE

ARM, RELAY & 90109-12010 BOLT M10 x 1.25 31 – 49 1

ARM (3.1 – 4.9)
92902-12600 WASHER,
PLAIN
90185-12011 NUT, SELF
LOCKING

ARM & REAR 90109-12010 BOLT M10 x 1.25 31 – 49 1

(3.1 – 4.9)
ARM 92902-12600 WASHER,
PLAIN
90185-12011 NUT, SELF
LOCKING

REAR 90105-10017 BOLT, M10 x 1.25 31 – 49 1

CUSHION & FLANGE (3.1 – 4.9)

ARM, RELAY 95602-10200 NUT, U

FLANGE

REAR CUSHION 95602-10200 NUT, U M10 x 1.25 31 – 49 1

and FRAME FLANGE (3.1 – 4.9)
90105-10609 BOLT,
FLANGE

ADJUST NUT 90101-08013 BOLT, M8 x 1.25 12 – 19 2

for CHAIN HEXAGON (1.2 – 1.9)

PULLER 95302-08600 NUT,

HEXAGON
90201-08057 WASHER,
PLAIN

HANDLE, 91314-08030 BOLT, M8 x 1.25 23 – 28 2

CROWN & HEXAGON (2.3 – 2.8)
SOCKET
OUTER TUBE HEAD

HANDLE, 90170-28419 NUT, M28 x 1.0 100 – 125 1

CROWN & HEXAGON (10.0 – 12.5)

STEERING
SHAFT

HANDLE & 91314-08025 BOLT, M8 x 1.25 28 – 35 2

OUTER TUBE HEXAGON (2.8 – 3.5)
SOCKET
HEAD

– 66 –
Chassis

To be tightened Part No. Part Name Thread dia. Tightening Q’ty Remarks
x torque N•m
pitch (kgf•m)
HANDLE and 91380-06025 BOLT, M6 x 1.0 5–8 2
HANDLE, HEXAGON (0.5 – 0.8)
SOCKET
CROWN HEAD

STEERING 90179-30691 NUT M30 x 1.0 40 – 64 1

SHAFT and (4.0 – 6.4)

RING NUT 12 – 15
(1.2 – 1.5)

OUTER TUBE 91314-08030 BOLT, M8 x 1.25 20 – 25 x 2 4

and UNDER HEXAGON (2.0 – 2.5 x 2)
SOCKET
BRACKET HEAD

FUEL TANK & 90119-05015 BOLT, M5 x 0.8 3–5 4

FUEL PUMP HEXAGON (0.3 – 0.5)
WITH
WASHER

FRONT STAY 90110-06233 BOLT, M6 x 1.0 3–5 1

for FUEL TANK HEXAGON (0.3 – 0.5)
SOCKET
& FUEL TANK

REAR STAY for 90111-06071 BOLT, M6 x 1.0 5–8 4

FUEL TANK HEXAGON (0.5 – 0.8)
SOCKET
& REAR FRAME BUTTON

REAR STAY for 95812-06090 BOLT, M6 x 1.0 3–5 1

FUEL TANK FLANGE (0.3 – 0.5)

& FUEL TANK 95702-06500 NUT,

FLANGE

FRONT WHEEL 90179-24004 NUT M24 x *** 100 – 130 1

SHAFT & NUT (10.0 – 13.0)

REAR WHEEL 90185-24007 NUT, SELF M24 x 1.5 160 – 220 1

SHAFT & NUT LOCKING (16.0 – 22.0)

FRONT 90105-10397 BOLT, M10 x 1.25 30 – 40 4

CALIPER & FLANGE (3.0 – 4.0)

FRONT FORK

DISC BRAKE & 2CR-2589H-00 SCREW M6 x 1.0 14 – 19 10

WHEEL (FRONT) (1.4 – 1.9)

DISK BRAKE & 90149-08009 SCREW M8 x 1.25 23 – 37 5

PLATE DISK 1 (2.3 – 3.7)

REAR WHEEL 90185-10011 NUT, SELF M10 x 1.25 90 – 109 5

SPROCKET & LOCKING (9.0 – 10.9)

CLUTCH HUB

SPLIT BOLT for 91314-08040 BOLT, M8 x 1.25 18 – 23 4

FRONT AXLE HEXAGON (1.8 – 2.3)
SOCKET
HEAD

– 67 –
For reference
Tightening torque N•m
M5 × 0.8 4.5 – 7.0
M6 × 1.0 7.5 – 12
M8 × 1.25 18 – 28
M10 × 1.25 37 – 58
M12 × 1.25 68 – 108
M14 × 1.5 105 – 167

– 68 –
Tightening the Cylinder Head
1. In the following order (1→10), apply initial
tightening of 10 N•m (1.0 kgf•m).
2. In the following order (1→10), apply
additional tightening of 25 N•m (2.5 kgf•m).
3. In the following order (1→10), apply
additional tightening of 45 N•m (4.5 kgf•m).
4. In the following order (1→10), loosen each
bolt. Then, tighten at 15 N•m (1.5 kgf•m)
and tighten at rotating angle of 160°.
(Note: Do not loosen all bolts at once.
Repeat loosening and tightening operation
one by one bolt.)

TIP

The numbers 1 to 10 show the sequence

in which the bolts are tightened.
Apply engine oil to the bearing surface
and thread part of the bolt.
Use a new bolt only. (Do not reuse)

6 2 4 10
8

9 3 1 5 7

10

– 69 –
Installing the Crankcase
1. T i ghten t he b o lt s in t he t i ghtening TIP
sequence of 1 to 10 to 20 N•m (2.0 kg•m). The numbers 1 to 40 show the sequence
2. After loosening the bolts once in the in which the bolts are tightened.
tightening sequence of 1 to 10, retighten Apply engine oil to the bolts 1 to 10, 21
them one by one to 15 N•m (1.5 kg•m). to 27 and 29 to 39, and the both sides of
(Note: Do not loosen all bolts at once. the washer. Apply screw rock agent to
Repeat loosening and tightening operation the bolts 28 and 40 (apply engine oil to
one by one bolt.) the bearing surface only). Apply oil to the
3. Retighten the bolts in the tightening thread part, bearing surface and O-RING
sequence of 1 to 10 to a turn-of-nut angle part of the bolts 11 to 20. Do not reuse a
of 75°±5°. mended O-RING.
4. T i ghten t he b o lt s in t he t i ghtening
sequence of 11 to 20 to 24±2 N•m (2.4±0.2
kgf•m).
5. T i ghten t he b o lt s in t he t i ghtening
sequence of 21 to 40 to 10±2 N•m (1.0±0.2
kgf•m).

21 34
31
15 32 33
17 11 13

18 16 23 12 14 35
30
7 5 1 3 9

10 4 2 6 8
29
28 26 24
25 22
19
27

38 20
40
39 37 36

40

– 70 –
Procedure to tighten the aluminum bolts
1. In the following order, tighten the bolt at
6N•m (0.6kgf•m). 8
2. In the following order, loosen each bolt, 7
1
tighten at 3 N•m (0.3 kgf•m), and apply
snap and angle tightening at rotating angle 6
of 90°. 2
(Note: Do not loosen all bolts at once.
5 3
Repeat loosening and tightening operation 4
one by one bolt.)

TIP 1
10 2
The numbers 1 to 12 show the sequence
9
in which the bolts are tightened.
3
Use a new bolt only. (Do not reuse)
8 4

7 5
1 2 6

3
5

6 7
8
9
5
10
4
11

3 12
2 1

2
1 3

4
8

7 5
6

– 71 –
When replacing aluminum bolts with iron bolts
Use the following table as a reference when
replacing aluminum bolts with iron bolts.

To be tightened Part No. Part Name Thread dia. Tightening Q’ty Remarks
x torque N•m
pitch (kgf•m)
Install COVER, 90110-06390 BOLT, M6 x 1.0 12±2 12 APPLY TO SCREW
STRAINER HEXAGON (1.2±0.2) ROCKING
SOCKET STRAINER
COVER

Install COVER 90110-06387 BOLT, M6 x 1.0 12±2 8 ACM

CRANK CASE 1 HEXAGON (1.2±0.2) COVER
SOCKET
(15411)

Install COVER 90110-06388 BOLT, M6 x 1.0 12±2 10 CLUTCH

CRANK CASE 2 HEXAGON (1.2±0.2) COVER
SOCKET
(15421)

Install COVER 1 90110-06396 BOLT, M6 x 1.0 12±2 5 CAM CHAIN

(15416) HEXAGON (1.2±0.2) COVER
SOCKET

Install COVER 90110-06387 BOLT, M6 x 1.0 12±2 8 BREATHER

(15413) HEXAGON (1.2±0.2) COVER
SOCKET

– 72 –
Procedure to install the engine (unchangeable)
1. Attach the two engine adjusting bolts 1 to
TIP
the frame COMP. temporarily.
For information about tightening torque
2. Fit the engine installation position to the
and requirement for lubricant agent, see
frame COMP and attach the bolts 2 and 3
the list of tightening torque.
temporarily.
3. Attach the bolt 4 temporarily.
4. Attach the engine mount boss 5 and 6 to
the frame COMP. temporarily and then
attach the bolt 7 temporarily.
5. Tighten the two engine adjusting bolts 1 at
specified torque.
Check that the bearing surface of the bolts
1 completely fit the surface of the engine.
6. Tighten the two nuts 8 and 9 at specified
torque. Tighten the nut 8 (lower side) at
first, then tighten the nut 9 (upper side).
7. Tighten the bolt 4 at specified torque.
8. Tighten the bolt 7 at specified torque.

9 4

7 5 2

6
8

1
FW
D

– 73 –
Procedure to install the pivot shaft peripheral parts
1. Tighten the pivot shaft 1 at specified
TIP
torque.
For information about tightening torque
2. Tighten the nut 2 at specified torque.
and requirement for lubricant agent, see
3. Tighten the nut 3 (self-rocking) at
the list of tightening torque.
specified torque.
Be sure to secure the pivot shaft 1 so that
it is not co-rotated.

2
90201-30016
WASHER, PLAIN

Apply grease to the outer

R
surface of the pivot shaft.
L

90201-20026
WASHER, PLAIN
3

– 74 –
 4 Headlight Cord Wiring Diagram

– 75 –
5 YZF-R1 Wiring Diagram

001 BTRY
002 ST_RELAY
003 ST_MOTOR
004 REC_REGU
005 MAIN_SW
006 RELAY_ASSY
007 IG_COIL_1
008 I G_COIL_2
009 IG_COIL_3
010 IG_COIL_4
011 E-SD_SOLENOID
018 SW.HANDLE_L
019 SW.HANDLE_R
020 CRANK_SHAFT_SENSOR
021 CAM_SHAFT_SENSOR
024 PRESSURE_SENSOR(Pb)
025 PRESSURE_SENSOR(Pa)
026 AIR_TEMP_SENSOR
027 WATER_TEMP_SENSOR
029 GEAR_PO_SENSOR
030 TPS
031 APS
033 VI_MOTOR
034 ECU
035 OIL_SW.
038 THROTTLE_MOTOR
042 INJECTOR_#11
043 INJECTOR_#21
044 INJECTOR_#31
045 INJECTOR_#41
046 INJECTOR_#12
047 INJECTOR_#22
048 INJECTOR_#32
049 INJECTOR_#42
050 MAIN_FUSE
051 FUSE_BOX1
054 METER
055 ABS_ECU
056 FR.WHEEL_SENSOR
057 RR.WHEEL_SENSOR
069 FUEL_PUMP
071 IMU
077 EG_EARTH
073 SERVICE_TOOL
074 NEUTRAL_SW
079 J/C07
080 ACM
081 SCU
082 FC_MOTOR
083 FR_MOTOR
084 RC_MOTOR
085 RR_MOTOR
086 SD_MOTOR(OP)
095 BONDA1
096 BONDA 2
097 BONDA 3
103 CCU
100 J/C08
101 J/C09
104 GPS.
110 A-MAP_SELECT_SW.
111 POWER_SUPPLY
112 PC_I/F
113 POWER_SUPPLY_2

– 76 –
 R1180501Rev

– 77 –
Published by YAMAHA MOTOR ENGINEERING co., LTD