timing on 20valve yamaha r1

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YAMAHA XS650H/ SH Supplementary Service Manual

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Filed Under (Yamaha) by admin on 21-11-2010

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Ignition timing check 1. Ignition timing is checked with a timing light by observing the position of the rotor pointer and the marks stamped on the timing plate. The timing plate is marked as follows. “ll” Firing range for No. 1 (L.H.) “T” Top Dead Center for No. 1, fL.H.1 cylinder 2. Connect the timing light to the left cylinder spark plug lead wire. 3. Start the engine and keep the engine speed as specified. Use a tachometer to check the engine speed. B. PICK-UP COIL ASSEMBLY The method of mounting the pick-up coil assembly is changed for easier service work. Thus, the followings “Pick-up coil assembly removal” and “Pick-up coil assembly reinstallation” should be changed. Pick-up coil assembly removal Remove the pick-up coil securing screws and remove the pick-up coil assembly. Pick-up coil assembly reinstallation Install the pick-up coil assembly on to the stator assembly. _ L 4. Specified engine speed: 1,200 r/min The rotor pointer should be within the limits of ” fl ” on the timing plate. If it exceeds the limits or does not steady, check the timing plate for tight- ness and/or ignition system for damage. NOTE: Ignition timing is not adjustable. C. FUEL LEVEL The carburetor is furnished with a drain screw to provide easy access to service work. Thus, the following “Fuel level measurement” should be added. Fuel level measurement NOTE: Before checking the fuel level, note the follow- ing: 1. Place the motorcycle on a level surface. 2. Adjust the motorcycle position by placing a suitable stand or a garage jack under the engine so that the carburetor is positioned vertically. 1. 2. Connect the level gauge (special tool) or a vinyl pipe of 6 mm (0.24 in) in inside diameter to the float bowl nozzle left or right side carburetor. Set the gauge as shown and loosen the drain screw 3. Start the engine and stop it after a few minutes of run. This procedure is neces- sary to obtain the correct fuel level. NOTE: Make sure the fuel petcock is “ON” or “RES” oosition. 4. Note the fuel level and bring the gauge to the other end of the carburetor line and repeat step 3 above. Note the fuel level again and compare it with the previous gauge reading. They should be equal. If not, place a suitable size of wooden piece or the. alike under the center stand and adjust. 5. Check the fuel level one by one. The level should be in the specified range.

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ULTIMA IGNITION MODULE AND KIT INSTALLATION MANUAL FOR HARLEY DAVIDSON

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Filed Under (Harley Davidson) by admin on 03-03-2011

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Disconnect battery. 2. Mark location of timing plate in relation to inside of cam cover. This will give a starting point for timing on new module. Remove old ignition if applicable (see manual) Clymer, Haynes. 3. If your bike is not equipped with timing rotor M/W# 53-528 OEM#32402-83 you must buy one (included in kit). Also a single fire coil is needed (included in kit) M/W# 53-632. Any single fire coil rated 2-4 ohms can be used. NO SOLID CORE PLUG WIRES (copper, silver) they will damage the unit. 4. Install module: helpful hints, early model nose cones, i.e. Shovel Heads, the hole for the wire may need to be drilled out. Align with previously scripted mark for timing. Use lockwashers for stand offs for correct clearance of cover plate. Run wire loom. 5. Connect wires, see wiring diagram. Tape unused wires, green or brown. 12v to tach (brown) will damage module. Set timing. 1996 and later should not be timed 20˚ BTDC as the OEM module, but at 35˚ BTDC. Use this mark when using timing light. If VOESswitch is not used you must ground VOES wire (green) while timing. Refer to manual for correct identification of timing marks. At start up and timing, set spark advance in middle position. FUNCTION SWITCHES LED timing indicator light: When out, shows TDC. When ignition is on, LED will light up. When engine is cranking LED will blink. Electric Start/Kickstart: Set accordingly. VOES/Race mode: VOES switch lets the motor run smoother and improves gas mileage. If you don’t use it or add one tape up green wire and switch to race. VOES switch to use, M/W# 53-652. Spark advance: High compression motors should use race mode and 93 octane or better gas. Changing from VOES to race changes advance curves. Agood rule of thumb is if the engine knocks when throttle is applied in high gear, turn back spark advance curve until it stops engine knock. RPMlimiter: Set at desired RPM to cut engine power. Rear Cylinder: This is for racing and should be set at a dyno. +/-5˚. Rear cylinder timing is achieved through this adjuster. Most should dial to middle setting and leave alone. After all switches are set, install cover with supplied gasket and feel the increased performance of a solid state single fire ignition. Again, we remind you, if you don’t feel confident about installing this unit, let a qualified mechanic do it and be assured you are getting the best performance and gas mileage possible.

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YAMAHA MOTOR CORPORATION, U.S.A. STREET & ENDURO MOTORCYCLE LIMITED WARRANTY

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Filed Under (Yamaha) by admin on 27-12-2011

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GENERALEXCLUSIONS from this warranty shall include any failures caused by: a. Competition or racing use. b. Installation of parts or accessories that are not qualitatively equivalent to genuine Yamaha parts. c. Abnormal strain, neglect, or abuse. d. Lack of proper maintenance. e. Accident or collision damage. f. Modification to original parts. g. Damage due to improper transportation. SPECIFIC EXCLUSIONS from this warranty shall include parts replaced due to normal wear or routine maintenance. THE CUSTOMER’S RESPONSIBILITY under this warranty shall be to: 1. Operate and maintain the motorcycle as specified in the appropriate Owner’s Manual. 2. Give notice to an authorized Yamaha motorcycle dealer of any and all apparent defects within ten (10) days after discovery, and make the machine available at that time for inspection and repairs at such dealer’s place of business. You may locate your nearest authorized Yamaha dealer through your local telephone directory. WARRANTY TRANSFER: To transfer any remaining warranty from the original purchaser to any subsequent purchaser, it is imperative that the machine be inspected and registered for warranty by an authorized Yamaha motorcycle dealer. In order for this warranty to remain in effect, this inspection and registration must take place within ten (10) days after transfer. Areasonable dealer imposed fee may be charged for the inspection. In no case will warranty be extended beyond the original period. EMISSIONS CONTROLSYSTEM WARRANTY Yamaha Motor Corporation, U.S.A. also warrants to the ultimate purchaser and each subsequent purchaser of each Yamaha motorcycle covered by this warranty with a displacement of 50cc or greater, that the vehicle is designed, built, and equipped so as to conform at the time of sale with all U.S. emissions standards applicable at the time of manufacture and that it is free from defects in materials and workmanship which would cause it not to meet these standards within the periods listed immediately below. Failures other than those resulting from defects in material or workmanship which arise solely as a result of owner abuse and/or lack of proper maintenance are not covered by this warranty.

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Harley-Davidson Electronic Ignition Module Installation instructions

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Filed Under (Harley Davidson) by admin on 23-04-2012

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Step 1: Switch main dashboard switch to “off” position (Ignition& light switch) Step 2: Disconnect negative (ground) cable from the Battery Step 3: Remove the Condenser and Breaker points from the circuit breaker timing base. Step 4: Disconnect advance/ retard cable from timing base Step 5: Remove timing base from timer shaft and housing (see your manual for instructions) Step 6: Remove circuit breaker wire stud or circuit breaker to coil wire assembly from timing base Step 7: Remove circuit breaker wire from Ignition coil, and mark terminal on coil with piece of tape. Step 8: Install the Electronic Ignition Module on the timing base. Mount this short black wire to one on the timer base screws by keeping some slack in this wire so the timing base can turn free. Solder the flag terminal to this short black wire and mount it under the timer to motor bolt. This way of mounting provides a much better grounding. Do NOT use the screws (number 1 or 2 screws from picture below) from the timing base!!!! Step 9: Now three wires pass this hole via the rubber grommet. Figure 1 Figure 2 Step 10: Reinstall the timer base on the timer shaft housing, and keep some slack in the wires before protruding the hole in the timer shaft housing, and secure with ground spring and cover retainer. Reconnect the advance/retard cable to the timer base. Step 11: Route the two long wires to the ignition coil. Check in the HD service manual for a proper route to the ignition coil. (Keep away from hot surfaces like exhaust systems). Cut the wires to the exact length necessary for mounting. Step 12: Determine the exact length of the wire loom. Keep in mind that one end of the loom enters the timer shaft housing by 1cm. Cut the loom to the proper length. Step 13: Insert both wires in the loom. Strip both wire ends and solder the two flag terminals on the wires. Step 14: Connect the red wire to the ignition coil, on the terminal where the 6 or 12 volt is supplied to. This terminal has at minimum one wire connected which runs to the main switch. Step 15: Connect the black wire to the ignition coil on the terminal which is empty, and has piece of tape on it. (Old place where the circuit breaker wire was connected to) Step 16: Install the trigger rotor on the timer shaft cam, and tighten the hex screw by using the hex key tool. Do not over tighten the screw! Step 17: Check for clearance between trigger rotor and Electronic Ignition Module. Appropriate clearance is between 0,5mm and 1,5mm . Minor adjustments can be made by unlocking the two screws and slightly shift/move the Electronic Ignition Module. Check if the rotor moves free. Timing instructions: Remove the spark plugs from the engine, but keep them connected to the spark coil cables and engine ground. This enables normal operation of the spark, and prevents unwanted engine firing on compression stroke. See service manual or handbook for timing instructions of your model Step 18: Reconnect the negative (ground) cable to the battery. Step 19: Switch main power to “on” position. The red light in the Electronic Ignition Module might already light up. If not, turn the kick starter slowly. The red light is on while charging (closed points)the Ignition coil, facing solid metal of the trigger rotor. The light goes off (open points) when the end of the solid surface of the trigger rotor passes the centre of the Electronic Ignition Module. At that point a spark is generated by the coil

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Yamaha YZ 250F Camshafts REMOVAL AND INSTALLATION MANUAL

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Filed Under (Yamaha) by admin on 30-12-2011

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Remove the 4 bolts that hold the exhaust cam cap in place, lift the cam cap off. It may be necessary to pry very lightly on the cap to lift it off its dowel pins. Do not use the cam lobes as the pry point. Be careful not to drop the dowels and also be careful to not lose the half moon shaped retainer for the bearing under the cam cap. Remove the 6 bolts that hold the intake camshaft cap and lift the cam cap off the camshaft, again, be careful to not drop the retainer or dowels. Lift the intake camshaft out of its pocket in the cylinder head casting. Remove the cam chain from the sprocket, set the stock camshaft aside. Lift the exhaust cam out of its pocket in the cylinder head casting and remove the chain from the sprocket. Do not drop the cam chain, dangle it over the side of the engine while keeping slight upward pressure on the chain to maintain its position on the drive sprocket on the crankshaft. Fit the half moon shaped retainers in the grooves of the Hot Cams camshaft bearings to ensure good fit, set retainers aside for the time. Using assembly lube, lube the shim buckets, bearing surfaces for the camshafts in the cylinder head, and pack some in the camshaft bearings. Set the exhaust cam into the cylinder head casting while at the same time fitting the cam chain over the sprocket. Make sure that you keep all the cam chain slack to the back of the engine. The cam chain pulls the camshaft sprockets in a counter clockwise direction and the slack of the chain must be kept on the cam chain tensioner side of the engine. The exhaust cam has two timing marks on it. When correctly installed one mark will be at the 9 o’clock position and the other mark will be at the 12 o’clock position. When correctly timed the mark at 9 o’clock will be aligned with the valve cover gasket surface. Repeat the above process for the intake camshaft. Again, make sure you keep the chain slack to the cam chain tensioner side of the engine. Check to be sure the crankshaft is still at TDC. The intake cam has two timing marks also. One at 12 o’clock and the other at 3 o’clock. When both cams are installed correctly, the valve cover gasket surface will form a straight line through the exhaust timing mark at 9 o’clock and the intake timing mark at 3 o’clock

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Yamaha YZF-R6 SPECIFICATION AND OWNER'S MANUAL

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Filed Under (Yamaha) by admin on 19-11-2010

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Shift timing indicator light This indicator light can be set to come on and go off at the desired engine speeds and is used to inform the rider when it is time to shift to the next higher gear. The electrical circuit of the indicator light can be checked by turning the key to “ON”. If the indicator light does not come on for a few seconds, then go off, have a Yamaha dealer check the electrical circuit. (See pages 3-7-3-10 for a detailed explanation of the function of this indicator light and on how to set it.) EAU04923* Coolant temperature warning light “” This warning light comes on when the engine overheats. When this occurs, stop the engine immediately and allow the engine to cool. The electrical circuit of the warning light can be checked by turning the key to “ON”. If the warning light does not come on for a few seconds, then go off, have a Yamaha dealer check the electrical cir- cuit. Multi-function display The multi-function display is equipped with the following: a speedometer (which shows the riding speed) an odometer (which shows the total distance traveled) two tripmeters (which show the distance traveled since they were last set to zero) a fuel reserve tripmeter (which shows the distance traveled since the fuel level warning light came on) a clock a self-diagnosis device a display brightness and shift timing indicator light control mode NOTE: Be sure to turn the key to “ON” before using the “SELECT” and “RESET” buttons. To switch the speedometer and odometer/tripmeter displays between kilometers and miles, press the “SELECT” button and “RESET” button together for at least two seconds. Odometer and tripmeter modes Pushing the “SELECT” button switches the display between the odometer mode “ODO” and the tripmeter modes “TRIP 1″ and “TRIP 2″ in the following order: ODO → TRIP 1 → TRIP 2 → ODO If the fuel level warning light comes on (see page 3-2), the odometer display will automatically change to the fuel reserve tripmeter mode “F-TRIP” and start counting the distance traveled from that point. In that case, pushing the “SELECT” button switches the display between the various tripmeter and odometer modes in the following order: F-TRIP → TRIP 1 → TRIP 2 → ODO → F-TRIP

YAMAHA YZ MOTOCROSS ENGINE specification

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Filed Under (Yamaha) by admin on 13-11-2010

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YZ450F Engine Reshaped intake ports The YZ450F’s innovative 5-valve cylinder head design is one of the most sophisticated in the category, and plays a vital role in enabling this high-tech MX bike maintain its well-documented superiority on the race track. For 2008 the combustion efficiency of this advanced cylinder head is further improved with the introduction of reshaped intake ports which enhance the bike’s low to mid-range performance. New exhaust camshaft profile Yamaha Motor Europe N.V. Page 5 of 33
In order to optimise the significant performance gains of the new intake port design, the latest YZ450F’s 5-valve cylinder head is equipped with new camshafts featuring reshaped Yamaha Motor Europe N.V. Page 6 of 33
profiles. The inlet valve timing has been adjusted, the overlap is modified and exhaust lift is revised to create an idealised balance of intake and exhaust operations for increased combustion efficiency and improved performance in the important low to mid-range zone. Reduced piston clearance The YZ450F powerplant is already one of the most advanced 4-stroke engine designs in the MX world, featuring cutting-edge technology which gives it a real advantage. Extensive use of lightweight materials has enabled Yamaha to create a light, compact and high-revving engine which produces a remarkably wide band of hard hitting power – and for 2008 our engineers have further reduced cylinder/piston tolerances of the 95mm diameter piston in order to enhance the overall package. These reductions may only be measurable in terms of microns, yet the differences are most definitely tangible, and include increased torque output, smoother running and quieter operation. New 94dB silencer Complying with the new FIM94dB(A) regulations is a new stainless steel silencer which maintains the machine’s strong low to mid-range power output, while reducing overall noise.

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YAMAHA V-Star 1100 Motorcycle Enhancements Remote Oil Filter Installation Manual

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Filed Under (Yamaha) by admin on 10-11-2010

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Removing Your Old Filter and Beauty Cover In order to install the new Remote Oil Filter Kit, you’ll need to remove the stock Yamaha “beauty cover” and the old filter and filter cover. Remove the engine parts necessary to access the stock filter as outlined in the V-Star owner’s manual. The parts should come off in this order: 1. Muffler assembly 2. Front exhaust pipe 3. Rear brake reservoir cover bolt and brake cover (the reservoir should not be removed, it can remain in place and be moved aside as needed) 4. Right floorboard (this can be simply loosened, by loosening the two bolts underneath) With the above parts removed, you can remove the Allen bolts holding the beauty cover and filter cap from your engine. There are five Allen bolts holding the beauty cover (so named, because most of the cover just covers the chromed side of the engine There are five bolts holding the cover. Ignore the three on the “Yamaha” cap in the middle – these just hold the Yamaha cap to the beauty cover itself. One bolt is hidd – in this picture – just be the Yamaha ca en low p. The bottommost bolt on the beauty cover will likely leak some oil when you remove it – it holds on the inner oil filter cover. Once you remove the beauty cover, you can remove the oil filter cover, and the oil filter Keep these two “O” rings, you’ll need them for the remote kit Old oil filter. Toss it away; you’ll never need one again! Throw away the old filter, and carefully remove the orange and black “O” rings from the filter cover (see picture above). These two “O” rings will go on the new engine cap in the same order as on the old filter cover. “O” ring for bottom bolt. When the beauty cover and filter cover are removed, be sure not to lose the tiny “O” ring that the bottom bolt goes through. Preparing the Remote Oil Filter Kit Remove the orange and black “O” rings from the stock filter cover plate, and place them on the Remote Oil Filter Kit engine cap – black on the inside, orange on the outside – just like on the stock filter cover.

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YAMAHA Installing the Motorcycle Enhancements Remote Oil Filter

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Filed Under (Yamaha) by admin on 17-01-2012

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In order to install the new Remote Oil Filter Kit, you’ll need to remove the stock Yamaha “beauty cover” and the old filter and filter cover. Remove the engine parts necessary to access the stock filter as outlined in the V-Star owner’s manual. The parts should come off in this order: 1. Muffler assembly 2. Front exhaust pipe 3. Rear brake reservoir cover bolt and brake cover (the reservoir should not be removed, it can remain in place and be moved aside as needed) 4. Right floorboard (this can be simply loosened, by loosening the two bolts underneath) With the above parts removed, you can remove the Allen bolts holding the beauty cover and filter cap from your engine. There are five Allen bolts holding the beauty cover (so named, because most of the cover just covers the chromed side of the engine
There are five bolts holding the cover. Ignore the three on the “Yamaha” cap in the middle – these just hold the Yamaha cap to the beauty cover itself. One bolt is hidd – in this picture – just be the Yamaha ca en low p

YAMAHA YZF-R1R/ YZF-R1RC OWNER'S MANUAL

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Filed Under (Yamaha) by admin on 03-12-2010

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1. Right turn signal indicator light “” 2. Fuel level warning light “” 3. Oil level warning light “” 4. Neutral indicator light “” 5. Engine trouble warning light “” 6. High beam indicator light “” 7. Left turn signal indicator light “”
INSTRUMENT AND CONTROL FUNCTIONS 3-3 3 EAU04895 Oil level warning light “” This warning light comes on when the engine oil level is low. The electrical circuit of the warning light can be checked by turning the key to “ON”. If the warning light does not come on for a few seconds, then go off, have a Yamaha dealer check the electrical cir- cuit. NOTE: Even if the oil level is sufficient, the warning light may flicker when riding on a slope or during sudden acceleration or deceleration, but this is not a malfunction. This model is also equipped with a self-diagnosis device for the oil level detection circuit. If the oil level detection circuit is defective, the following cycle will be repeated until the malfunction is corrected: The oil level warning light will flash ten times, then go off for 2.5seconds. If this occurs, have a Yamaha dealer check the motor- cycle. EAU00061 Neutral indicator light “” This indicator light comes on when the transmission is in the neutral position. EAU04896 Engine trouble warning light “” This warning light comes on or flashes when an electrical circuit monitoring the engine is defective. When this occurs, have a Yamaha dealer check the self-diagnosis system. (See page 3-7 for an explanation of the self-diagnosis device.) The electrical circuit of the warning light can be checked by turning the key to “ON”. If the warning light does not come on for a few seconds, then go off, have a Yamaha dealer check the electrical circuit. EAU00063 High beam indicator light “” This indicator light comes on when the high beam of the headlight is switched on

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