YAMAHA YZF-R1P YZF-R1PC ASSEMBLY MANUAL

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Filed Under (Yamaha) by admin on 26-02-2011

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PREPARATION To assemble the motorcycle correctly, supplies and working space are required. Supplies oils, greases, shop rags. Workshop The workshop where the motorcycle is assembled should be clean and large. The floor should be level. Self-protection Protect your eyes with suitable safety spectacles or safety goggles when using compressed air, when grinding or when doing any operation which may cause particles to fly off. Product hands and feet by wearing safety gloves or doing. SYMBOLS USED ON CRATE CARTON Contents of the transport package are fragile therefore it shall be handled with care. Indicates correct upright position of the transport package. Transport package shall be kept away from rain. Insertion of the lift arm from this side is prohibited. Lift arm inserting position. -1- UNPACKING 1. Remove the frame cover 1. NOTE: To remove the frame cover, cut the vinyl bands around the cover using a cutter or scissors. 2. Remove the bolts 2 (upper bracket). 3. Remove the bolt 3 (front tire). 4. Remove the packing frames 4 (upward and sideways). NOTE: Remove the bolts while holding frame. NOTE: Before starting the assembly, check for damaged or missing parts. The parts are contained in the cartan and the motorcycle for damage, scratches and other defects. -2- PARTS LOCATION 1 Carton box -3- 1 Carton box Screw, washer and special nuts (windscreen) Bolt (front master cylinder) Bolt (handle crown and handlebar) Nut (rear view mirror) Nut (front reflector) Front reflector Vinyl bag 1 Plugs (handle crown) Owner’s manual Rear view mirrors Windscreen – -5- 1. Handlebar 1 2 3 4 5 6 1 1 1 1 2 1 Reservoir tank (brake) Hexagon socket bolt Crown nut Hexagon socket bolt Cap Hexagon socket bolt * V * V V * d = 6 (0.24), r= 12 (0.47) d = 6 (0.24), r= 25 (0.98) d = 8 (0.31), r= 30 (1.18) 2. Front reflector A: Tighten the crown nut to specified torque. Tightening torque: 115 Nm (11.5 m • kg, 85.0 ft • lb) B: Tighten the bolt to specified torque. Tightening torque: 13 Nm (1.3 m • kg, 9.4 ft • lb) C: Tighten the bolt to specified torque. Tightening torque: 13 Nm (1.3 m • kg, 4.4 ft • lb) A: Tighten the screws to specified torque. Tightening torque: 40 Nm (4.0 m • kg, 29 ft • lb) 1 2 3 4 5 2 2 2 4 4 Reflector bracket Reflector Nut Washer Caliper bolt * V V * * d = 5 (0.20) d = 10 (0.39) d = 10 (0.39), r= 30 (1.18) 3. Clutch cable 1 Clutch cable 1 * A: Check the clutch lever for smooth action. CAUTION: Proper cable routing is essential to assure safe motorcycle operation. Refer to “CABLE ROUTING

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YAMAHA TZR50 X-POWER SERVICE MANUAL

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

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SPARES 1. Use only original Yamaha/MBK spares for all changes. Use the oils and /or greases recommended by Yamaha/MBK for assembly and adjustments. Other makes may have the same function and appearance but nevertheless be of lower quality. GASKETS, OIL SEALS AND O RINGS 1. When an engine is dismantled, all the gaskets, oil seals and O rings must be replaced. All the surfaces of all the gaskets and the lips of oil seals and O rings must also be cleaned. 2. When assembling, properly lubricate all bearings and matching parts. Apply grease to the lips of oil seals. WASHERS AND LOCKING TABS AND SPLIT PINS 1. All washers/locking tabs (1) and split pins have to be replaced and when locking tabs are removed and replaced they must be folded over the sides of the bolts or nuts, after these have been properly tightened. BEARINGS AND OIL SEALS 1. Install the bearings and oil seals with the makes or manufacturer numbers facing outwards. (This means that the printed letters should be visible). When installing oil seals, apply a thin layer of light lithium grease to the lips. Put plenty of oil on bearings when installing these. 7. Crankcase remover tool Ref. 90890-11030 This tool is used for dismantling the crankshaft or removing the crankcase. 8. Tools for installing the crankshaft. Ref. 90890-01284 These tools are used for installing the cranks- haft. 9. Crankcase installer (Magnetic flywheel side) Ref. 90890-11032 10. Seal installer (Selector axle) Ref. 90890-11033 11. Seal installer (Water pump) Ref. 90890-11034

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