Yamaha YZF1MLC Manuals

Manuals and User Guides for Yamaha YZF1MLC. We have 1 Yamaha YZF1MLC manual available for free PDF download: Service Manual

Yamaha YZF1MLC Service Manual

Yamaha YZF1MLC Service Manual (808 pages)

Brand: Yamaha | Category: Motorcycle | Size: 35.11 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 (for California Only)
  118
- Checking the Crankcase Breather Hose
  118
- Checking the Exhaust System
  118
- Checking the Throttle Body Joints
  118
- Adjusting the Clutch Lever Free Play
  119
- Checking the Air Induction System
  119
- Replacing the Air Filter Element
  119
- Checking the Brake Fluid Level
  120
- Checking the Brake Operation
  120
- Adjusting the Front Disc Brake
  121
- Adjusting the Rear Disc Brake
  121
- Checking the Front Brake Pads
  121
- Checking the Front Brake Hoses
  122
- Checking the Rear Brake Hose
  122
- Checking the Rear Brake Pads
  122
- Bleeding the Hydraulic Brake System (Abs)
  123
- Checking the Tires
  124
- Checking the Wheels
  124
- Checking the Swingarm Operation
  125
- Checking the Wheel Bearings
  125
- Drive Chain Slack
  125
- Lubricating the Swingarm Pivot
  125
- Checking and Adjusting the Steering Head
  126
- Lubricating the Drive Chain
  126
- Checking the Chassis Fasteners
  127
- Checking the Steering Damper
  127
- Lubricating the Brake Lever
  127
- Lubricating the Clutch Lever
  127
- Lubricating the Pedal
  127
- Lubricating the Steering Head
  127
- ADJUSTING the FRONT FORK LEGS (for YZF-R1)
  128
- Checking the Front Fork
  128
- Checking the Sidestand
  128
- Checking the Sidestand Switch
  128
- Lubricating the Sidestand
  128
- ADJUSTING the DAMPING FORCE of the FRONT FORK LEGS and REAR SHOCK ABSORBER ASSEMBLY (for YZF-R1M)
  130
- ADJUSTING the PRELOAD of the FRONT FORK LEGS (for YZF-R1M)
  130
- ADJUSTING the REAR SHOCK ABSORBER ASSEMBLY (for YZF-R1)
  132
- Checking the Rear Shock Absorber Assembly
  132
- ADJUSTING the PRELOAD of the REAR SHOCK ABSORBER ASSEMBLY (for YZF-R1M)
  134
- Checking the Connecting Arm and Relay Arm
  135
- Checking the Engine Oil Level
  135
- Changing the Engine Oil
  136
- Measuring the Engine Oil Pressure
  137
- Checking the Coolant Level
  138
- Changing the Coolant
  139
- Checking the Cooling System
  139
- Adjusting the Exup Cables
  141
- Adjusting the Rear Brake Light Switch
  142
- Checking and Charging the Battery
  142
- Checking and Lubricating the Cables
  142
- Checking the Front Brake Light Switch
  142
- Checking the Fuses
  142
- Checking the Throttle Grip
  142
- Adjusting the Headlight Beams
  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)
  
  157
- General Chassis (4)
  
  161
  - 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
    299
  - Installing the Engine
    299
  - Installing the Exhaust Pipe and Muffler
    300
- Camshafts
  
  301
  - Engine
    306
    
    Removing the Camshafts
    307
    
    Removing the Rocker Arms and Rocker Arm Shafts
    307
    
    Checking the Camshafts
    307
    
    Checking the Rocker Arms and Rocker Arm Shafts
    309
    
    Checking the Timing Chain and Camshaft Sprocket
    309
    
    Checking the Timing Chain Guides
    309
    
    Checking the Timing Chain Tensioner
    310
    
    Assembling the Timing Chain Cover
    310
    
    Installing the Rocker Arms and Rocker Arm Shafts
    310
    
    Installing the Timing Chain Cover
    311
    
    Installing the Camshafts
    312
- Cylinder Head
  
  316
  - Removing the Cylinder Head
    317
  - Checking the Cylinder Head
    317
  - Installing the Cylinder Head
    317
- Valves and Valve Springs
  
  319
  - Removing the Valves
    321
  - Checking the Valves and Valve Guides
    321
  - Checking the Valve Seats
    323
  - Checking the Valve Springs
    325
  - Checking the Valve Spring Seat
    325
  - Installing the Valves
    325
- Generator
  
  327
  - Removing the Generator
    329
  - Installing the Generator
    329
- Starter Clutch
  
  331
  - Removing the Starter Clutch
    332
  - Checking the Starter Clutch
    332
  - Installing the Starter Clutch
    332
- Electric Starter
  
  333
  - Checking the Starter Motor
    335
  - Assembling the Starter Motor
    335
- Oil Pump
  
  337
  - Removing the Oil Pan
    340
  - Checking the Sprocket and Chain
    340
  - Checking the Oil Pump
    340
  - Checking the Relief Valve
    340
  - Checking the Oil Delivery Pipes
    340
  - Checking the Oil Strainer
    340
  - Assembling the Oil Pump
    340
  - Installing the Oil Pump
    341
  - Installing the Oil Pan
    341
- Clutch
  
  343
  - Removing the Clutch
    347
  - Checking the Friction Plates
    347
  - Checking the Clutch Plates
    347
  - Checking the Clutch Springs
    348
  - Checking the Clutch Housing
    348
  - Checking the Clutch Boss
    349
  - Checking the Pressure Plate
    349
  - Checking the Primary Drive Gear
    349
  - Checking the Primary Driven Gear
    349
  - Checking the Pull Lever Shaft and Pull Rod
    349
  - Installing the Clutch
    349
- Shift Shaft
  
  352
  - Checking the Shift Shaft
    353
  - Checking the Stopper Lever
    353
  - Installing the Shift Shaft
    353
- Crankcase
  
  354
  - Disassembling the Crankcase
    357
  - Checking the Crankcase
    357
  - Assembling the Crankcase
    357
  - Installing the Crankcase Breather Cover
    359
  - Installing the Oil Pressure Switch
    360
  - Installing the Gear Position Sensor
    360
- Connecting Rods and Pistons
  
  361
  - Removing the Connecting Rods and Pistons
    362
  - Checking the Cylinder and Piston
    363
  - Checking the Piston Rings
    364
  - Checking the Piston Pin
    365
  - Checking the Connecting Rods
    365
  - Installing the Connecting Rod and Piston
    369
- Crankshaft and Balancer Shaft
  
  374
  - Removing the Crankshaft and Balancer Shaft
    375
  - Checking the Oil Nozzles
    375
  - Checking the Crankshaft
    375
  - Checking the Balancer Shaft
    377
  - Installing the Crankshaft
    378
  - Installing the Thrust Bearing
    379
  - Installing the Balancer Assembly
    379
- Transmission
  
  381
  - Removing the Transmission
    385
  - Checking the Shift Forks
    385
  - Checking the Shift Drum Assembly
    385
  - Checking the Transmission
    386
  - Assembling the Main Axle and Drive Axle
    386
  - Installing the Transmission
    387
  - Cooling System
    389
  - Fuel System
    407
  - Electrical System
    433
  - Self Diagnostic
    489

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