PDF Service And Repair Manual Yamaha YZFR1 1998 - 2 MB
This is the complete service and repair manual for the iconic 1998 Yamaha YZF-R1.
Covering everything from basic maintenance to a full engine rebuild, this guide is essential for any owner or mechanic.
It includes detailed specifications, step-by-step instructions, and clear photographs and diagrams to assist you with any task.
Keep your legendary superbike performing at its best with the same information used by professional dealership technicians.
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--- Page 1 ---
YZF-R1 ’98
4XV1-AE1
SERVICE MANUAL
--- Page 3 ---
GEN
IMPORTANT INFORMATION INFO
EB102000
IMPORTANT INFORMATION
PREPARATION FOR REMOVAL AND
DISASSEMBLY
1. Before removal and disassembly,
remove all dirt, mud, dust, and foreign
material.
2. Use only the proper tools and cleaning
equipment.
Refer to “SPECIAL TOOLS”.
3. When disassembling, always keep
mated parts together. This includes
gears, cylinders, pistons and other parts
that have been “mated” through normal
wear. Mated parts must always be
reused or replaced as an assembly.
4. During disassembly, clean all of the
parts and place them in trays in the
order of disassembly. This will speed up
assembly and allow for the correct
installation of all parts.
5. Keep all parts away from any source of
fire.
EB102010
REPLACEMENT PARTS
Use only genuine Yamaha parts for all
replacements. Use oil and grease recom-
mended by Yamaha for all lubrication jobs.
Other brands may be similar in function
and appearance, but inferior in quality.
EB102020
GASKETS, OIL SEALS AND O-RINGS
1. When overhauling the engine, replace
all gaskets, seals, and O-rings. All gasket
surfaces, oil seal lips, and O-rings must
be cleaned.
2. During reassembly, properly oil all mat-
ing parts and bearings and lubricate the
oil seal lips with grease.
1-2
--- Page 4 ---
GENERAL SPECIFICATIONS SPEC
SPECIFICATIONS
GENERAL SPECIFICATIONS
Item Standard Limit
Dimensions
Overall length 2,035 mm (except for N, S, SF) ----
2,095 mm (for N, S, SF) ----
Overall width 695 mm ----
Overall height 1,095 mm ----
Seat height 815 mm ----
Wheelbase 1,395 mm ----
Minimum ground clearance 140 mm ----
Minimum turning radius 3,400 mm ----
Weight
Wet (with oil and a full fuel tank) 198 kg ----
Dry (without oil and fuel) 177 kg ----
Maximum load (total of cargo, rider, 197 kg ----
passenger, and accessories)
2-1
--- Page 5 ---
CHASSIS SPECIFICATIONS SPEC
CHASSIS SPECIFICATIONS
Item Standard Limit
Frame
Frame type Diamond ----
Caster angle 24˚ ----
Trail 92 mm ----
Front wheel
Wheel type Cast wheel ----
Rim
Size 17 × MT3.50 ----
Material Aluminum ----
Wheel travel 135 mm ----
Wheel runout
Max. radial wheel runout ---- 1 mm
Max. lateral wheel runout ---- 0.5 mm
Rear wheel
Wheel type Cast wheel ----
Rim
Size 17 × MT6.00 ----
Material Aluminum ----
Wheel travel 130 mm ----
Wheel runout
Max. radial wheel runout ---- 1 mm
Max. lateral wheel runout ---- 0.5 mm
Front tire
Tire type Tubeless ----
Size 120/70 ZR17 (58W) ----
Model (manufacturer) MEZ3 FRONT (METZELER) (for GB) ----
TX15 (MICHELIN) (for N, D, NL, B, E, P,
I, GR)
Tire pressure (cold)
0 ~ 90 kg 250 kPa (2.5 kg/cm2, 2.5 bar) ----
90 ~ 197 kg 250 kPa (2.5 kg/cm2, 2.5 bar) ----
High-speed riding 250 kPa (2.5 kg/cm2, 2.5 bar) ----
Min. tire tread depth ---- 1.6 mm
2 - 11
--- Page 6 ---
TIGHTENING TORQUES SPEC
Crankcase tightening sequence:
2 - 21
--- Page 7 ---
OIL FLOW DIAGRAMS SPEC
1 Radiator cap
2 Thermostat
3 Thermostat housing
4 Water pump
2 - 31
--- Page 8 ---
CABLE ROUTING SPEC
Ô Route the wire harness and turn signal leads harness with a plastic locking tie.
under the rear cowling mounting post on the Ø Route the fuel tank overflow hose and fuel
tail/brake light bracket. tank breather hose in front of the crankcase
Insert the tail/brake light coupler and turn sig- breather hose and under the fuel hose and
nal leads between the tail/brake light and EXUP servomotor.
tail/brake light bracket. ∏ Fasten the sidestand switch lead, engine oil
Ò Position the ground coupler over the oil level level switch lead, generator lead, and wire
relay lead. harness with a plastic locking tie.
˜ Fasten the starter relay lead, ground lead,
and wire harness with a plastic locking tie.
ˆ Fasten the battery negative lead and wire
2 - 41
--- Page 9 ---
CHK
FUEL TANK ADJ
EB302010
FUEL TANK
Order Job/Part Q’ty Remarks
Removing the fuel tank Remove the parts in the order listed.
Rider seat Refer to “SEATS”.
1 Bolt
2 Bolt
3 Fuel sender coupler Disconnect.
4 Fuel hose NOTE:
Before disconnecting the fuel hose,
set the fuel cock to “OFF”.
5 Fuel tank overflow hose 1
6 Fuel tank breather hose 1
7 Fuel tank 1
8 Fuel tank side panel 2
For installation, reverse the removal
procedure.
3-4
--- Page 10 ---
ADJUSTING THE VALVE CLEARANCE/ CHK
SYNCHRONIZING THE CARBURETORS ADJ
g. Measure the valve clearance again.
h. If the valve clearance is still out of
specification, repeat all of the valve
clearance adjustment steps until the
specified clearance is obtained.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
7. Install:
• all removed parts
NOTE:
For installation, reverse the removal
procedure. Note the following points.
8. Install:
• timing chain guide (exhaust side)
• timing chain tensioner
• pickup coil rotor cover
• cylinder head cover
• spark plugs
Refer to “CAMSHAFTS” in chapter 4.
EB303010
SYNCHRONIZING THE CARBURETORS
NOTE:
Prior to synchronizing the carburetors,
the valve clearance and the engine
idling speed should be properly
adjusted and the ignition timing should
be checked.
1. Stand the motorcycle on a level surface.
NOTE:
Place the motorcycle on a suitable
stand.
2. Remove:
• rider seat
• fuel tank
• Refer to “SEATS” and “FUEL TANK”.
3 - 14
--- Page 11 ---
MEASURING THE COMPRESSION PRESSURE/ CHK
CHECKING THE ENGINE OIL LEVEL ADJ
Refer to the following table.
Compression pressure
(with oil applied into the cylinder)
Reading Diagnosis
Higher than with- Piston wear or
out oil damage → Repair.
Piston ring(-s),
valve(-s), cylinder
Same as without head gasket or
oil piston possibly
defective →
Repair.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
7. Install:
• spark plug 13 Nm (1.3 m · kg)
T.
R.
EB303070
CHECKING THE ENGINE OIL LEVEL
1. Stand the motorcycle on a level surface.
NOTE:
• Place the motorcycle on a suitable stand.
• Make sure that the motorcycle is
upright.
2. Start the engine, let it idle for several
minutes, and then stop it.
3. Check:
• engine oil level
The engine oil level should be between
the minimum level mark a and maxi-
mum level mark b.
Below the minimum level mark → Add
the recommended engine oil to the
proper level.
Recommended oil
Refer to the chart for the
engine oil grade which is
best suited for certain atmo-
spheric temperatures.
API standard
SE or higher grade
(Non-Friction modified)
3 - 24
--- Page 12 ---
CHECKING THE COOLANT LEVEL/ CHK
CHECKING THE COOLING SYSTEM ADJ
3. Start the engine, warm it up for several
minutes, and then turn it off.
4. Check:
• coolant level
NOTE:
Before checking the coolant level, wait a
few minutes until the coolant has set-
tled.
EB303230
CHECKING THE COOLING SYSTEM
1. Remove:
• bottom cowling
• side cowlings
Refer to “COWLINGS”.
2. Check:
• radiator 1
• radiator inlet hose 2
• radiator outlet hose 3
• oil cooler 4
• oil cooler inlet hose 5
• oil cooler outlet hose 6
• water jacket joint inlet hose 7
• water pump inlet pipe 8
• water pump outlet pipe 9
Cracks/damage → Replace.
Refer to “COOLING SYSTEM” in chap-
ter 5.
3. Install:
• side cowlings
• bottom cowling
Refer to “COWLINGS”.
3 - 34
--- Page 13 ---
ADJUSTING THE SHIFT PEDAL/ CHK
ADJUSTING THE DRIVE CHAIN SLACK ADJ
EB304081
ADJUSTING THE SHIFT PEDAL
NOTE:
The shift pedal position is determined
by the installed shift rod length a.
1. Measure:
• installed shift rod length a
Incorrect → Adjust.
Installed shift rod length
305 mm
2. Adjust:
• installed shift rod length a
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Loosen both locknuts 1.
b. Turn the shift rod 2 in direction b or
c to obtain the correct shift pedal
position.
Installed shift rod length
Direction b
increases.
Installed shift rod length
Direction c
decreases.
c. Tighten both locknuts.
d. Make sure that the installed shift rod
length is within specification.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EB304092
ADJUSTING THE DRIVE CHAIN SLACK
NOTE:
The drive chain slack must be checked at
the tightest point on the chain.
CAUTION:
ACHTUNG:
A drive chain that is too tight will over-
load the engine and other vital parts,
and one that is too loose can skip and
damage the swingarm or cause an acci-
dent. Therefore, keep the drive chain
slack within the specified limits.
1. Stand the motorcycle on a level surface.
WARNING
WARNING
Securely support the motorcycle so that
there is no danger of it falling over.
NOTE:
Place the motorcycle on a suitable stand
so that the rear wheel is elevated.
3 - 44
--- Page 14 ---
CHK
CHECKING THE TIRES ADJ
EB304170
CHECKING THE TIRES
The following procedure applies to both of
the tires.
1. Measure:
• tire pressure
Out of specification → Regulate.
WARNING
WARNING
• The tire pressure should only be
checked and regulated when the tire
temperature equals the ambient air
temperature.
• The tire pressure and the suspension
must be adjusted according to the
total weight (including cargo, rider,
passenger and accessories) and the
anticipated riding speed.
• Operation of an overloaded motorcy-
cle could cause tire damage, an acci-
dent or an injury.
NEVER OVERLOAD THE MOTORCYCLE.
Basic weight
(with oil
198 kg
and a full
fuel tank)
Maximum
197 kg
load*
Cold tire
Front Rear
pressure
250 kPa 250 kPa
Up to 90 kg
(2.5 kgf/cm2, (2.5 kgf/cm2,
load*
2.5 bar) 2.5 bar)
250 kPa 290 kPa
90 kg ~ max-
(2.5 kgf/cm2, (2.9 kgf/cm2,
imum load*
2.5 bar) 2.9 bar)
250 kPa 250 kPa
High-speed
(2.5 kgf/cm2, (2.5 kgf/cm2,
riding
2.5 bar) 2.5 bar)
* total of cargo, rider, passenger and
accessories
WARNING
WARNING
It is dangerous to ride with a worn-out
tire. When the tire tread reaches the
wear limit, replace the tire immediately.
3 - 54
--- Page 15 ---
CHK
CHECKING THE FUSES ADJ
3. Replace:
• blown fuse
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Set the main switch to “OFF”.
b. Install a new fuse of the correct
amperage.
c. Set the main switch to “ON” and ver-
ify if the electrical circuit is opera-
tional.
d. If the fuse immediately blows again,
check the electrical circuit.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Item Amperage Q’ty
Main fuse 30 A 1
Headlight
20 A 1
fuse
Signaling
20 A 1
system fuse
Ignition
15 A 1
fuse
Radiator
fan motor 7.5 A 1
fuse
Backup fuse
7.5 A 1
(odometer)
WARNING
WARNING
Never use a fuse with an amperage
other than that specified. Improvising or
using a fuse with the wrong amperage
rating may cause extensive damage to
the electrical system, cause the lighting
and ignition systems to malfunction
and could possibly cause a fire.
4. Install:
• rider seat
Refer to “SEATS”.
3 - 64
--- Page 16 ---
ENGINE ENG
Order Job/Part Q’ty Remarks
3 Clutch cable 1
4 Crankcase breather hose 1
5 Starter motor lead 1 Disconnect.
6 Ground lead 1 Disconnect.
7 Starter motor 1
8 Stator coil assembly coupler 1 Disconnect.
9 Pickup coil coupler 1 Disconnect.
10 Oil level switch connector 1 Disconnect.
11 Neutral switch 1
12 Speed sensor 1
For connecting, reverse the disconnec-
tion procedure.
4-5
--- Page 17 ---
CAMSHAFTS ENG
EB401701
INSTALLING THE CAMSHAFTS
1. Install:
• timing chain guide (intake side) 1
2. Install:
• intake camshaft sprocket
24 Nm (2.4 m · kg)
T.
R.
• exhaust camshaft sprocket
24 Nm (2.4 m · kg)
T.
R.
3. Install:
• exhaust camshaft
• intake camshaft
• exhaust camshaft caps
• intake camshaft caps
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the crankshaft clockwise.
b. When piston #1 is at TDC on the com-
pression stroke, align the TDC a
mark on the pickup coil rotor with the
crankcase mating surface b.
c. Install the timing chain onto both
camshaft sprockets and then install
the camshaft sprockets onto the cam-
shafts.
CAUTION:
ACHTUNG:
Do not turn the crankshaft when install-
ing the camshaft to avoid damage or
improper valve timing.
NOTE:
Make sure that the punch marks c on
the camshafts face up.
d. Install the exhaust and intake cam-
shaft caps.
Camshaft cap bolt
10 Nm (1.0 m • kg)
T.
R.
NOTE:
Make sure that the punch marks c on
the camshafts are aligned with the
arrow marks d on the camshaft caps.
Out of alignment → Reinstall.
e. Remove the wire from the timing
chain.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4 - 15
--- Page 18 ---
VALVES AND VALVE SPRINGS ENG
2. Replace:
• valve guide
NOTE:
To ease valve guide removal and instal-
lation, and to maintain the correct fit,
heat the cylinder head to 100 ˚C in an
oven.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the valve guide with a valve
guide remover 1.
b. Install the new valve guide with the
valve guide installer 2 and valve
guide remover 1.
c. After installing the valve guide, bore
the valve guide with a valve guide
reamer 3 to obtain the proper valve-
stem-to-valve-guide clearance.
NOTE:
After replacing the valve guide, reface
the valve seat.
Valve guide remover
Intake (4.0 mm)
90890-04111
Exhaust (4.5 mm)
90890-04116
Valve guide installer
Intake (4.0 mm)
90890-04112
Exhaust (4.5 mm)
90890-04117
Valve guide reamer
Intake
90890-04113
Exhaust
90890-04118
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Eliminate:
• carbon deposits
(from the valve face and valve seat)
4. Check:
• valve face
Pitting/wear → Grind the valve face.
• valve stem end
Mushroom shape or diameter larger
than the body of the valve stem →
Replace the valve.
4 - 25
--- Page 19 ---
PICKUP COIL ENG
PICKUP COIL
Order Job/Part Q’ty Remarks
Removing the pickup coil and Remove the parts in the order listed.
pickup coil rotor
Rider seat and fuel tank Refer to “SEATS” and “FUEL TANK” in
chapter 3.
Bottom cowling and right side cowl- Refer to “COWLINGS” in chapter 3.
ing
Engine oil Drain.
Refer to “CHANGING THE ENGINE
OIL” in chapter 3.
Generator rotor cover Refer to “GENERATOR”.
1 Clutch cable 1
2 Clutch cable holder 1
3 Pickup coil lead holder 1
4 Pickup coil rotor cover 1
5 Pickup coil rotor cover gasket 1
6 Dowel pin 2
4 - 35
--- Page 20 ---
CLUTCH ENG
EB405450
CHECKING THE CLUTCH BOSS
1. Check:
• clutch boss splines
Damage/pitting/wear → Replace the
clutch boss.
NOTE:
Pitting on the clutch boss splines will
cause erratic clutch operation.
EB405460
CHECKING THE PRESSURE PLATE
1. Check:
• pressure plate 1
Cracks/damage → Replace.
• bearing 2
Damage/wear → Replace.
EB405470
CHECKING THE PULL LEVER SHAFT AND
PULL ROD
1. Check:
• pull lever shaft pinion gear teeth a
• pull rod teeth b
Damage/wear → Replace the pull rod
and pull lever shaft as a set.
2. Check:
• pull rod bearing
Damage/wear → Replace.
CHECKING THE STARTER CLUTCH
1. Check:
• starter clutch gear
• starter clutch idle gear
Chips/pitting/roughness/wear →
Replace the defective part(-s).
4 - 45
--- Page 21 ---
OIL PAN AND OIL PUMP ENG
3. Check:
• oil pump operation
Unsmooth → Repair or replace the
defective part(-s).
Refer to “WATER PUMP” in chapter 5.
EB411410
CHECKING THE RELIEF VALVE
1. Check:
• relief valve body 1
• relief valve 2
• spring 3
• O-ring 4
Damage/wear → Replace the defective
part(-s).
EB411421
CHECKING THE OIL DELIVERY PIPE AND
OIL PIPE
1. Check:
• oil delivery pipe 1
• oil pipe 2
Damage → Replace.
Obstruction → Wash and blow out
with compressed air.
EB411430
CHECKING THE OIL STRAINER
1. Check:
• oil strainer 1
Damage → Replace.
Contaminants → Clean with engine oil.
EB411701
ASSEMBLING THE OIL PUMP
1. Lubricate:
• inner rotor
• outer rotor
• impeller shaft
(with the recommended lubricant)
Recommended lubricant
Engine oil
4 - 55
--- Page 23 ---
CONNECTING RODS AND PISTONS ENG
EB412131
REMOVING THE CONNECTING RODS AND
PISTONS
The following procedure applies to all of
the connecting rods and pistons.
1. Remove:
• connecting rod cap 1
• big end bearings
NOTE:
Identify the position of each big end
bearing so that it can be reinstalled in its
original place.
2. Remove:
• piston pin clips 1
• piston pin 2
• piston 3
• connecting rod 4
CAUTION:
ACHTUNG:
Do not use a hammer to drive the piston
pin out.
NOTE:
• For reference during installation, put
identification marks on the piston
crown.
• Before removing the piston pin, deburr
the piston pin clip groove and the pis-
ton pin bore area in the piston. If both
areas are deburred and the piston pin
is still difficult to remove, remove it
with the piston pin puller 4.
Piston pin puller
90890-01304
3. Remove:
• top ring
• 2nd ring
• oil ring
NOTE:
To remove a piston ring, open the end
gap with your fingers and lift the other
side of the ring over the piston crown.
4 - 65
--- Page 24 ---
CRANKSHAFT ENG
EB412110
REMOVING THE CRANKSHAFT
1. Remove:
• crankshaft 1
• crankshaft journal upper bearings
(from the upper crankcase)
NOTE:
Identify the position of each crankshaft
journal upper bearing so that it can be
reinstalled in its original place.
EB412403
CHECKING THE CRANKSHAFT
1. Measure:
• crankshaft runout
Out of specification → Replace the
crankshaft.
Max. crankshaft runout
0.03 mm
2. Check:
• crankshaft journal surfaces
• crankshaft pin surfaces
• bearing surfaces
Scratches/wear → Replace the crank-
shaft.
CHECKING THE CRANKSHAFT JOURNAL
BEARINGS
1. Measure:
• crankshaft-journal-to-crankshaft-jour-
nal-bearing clearance
Out of specification → Replace the
crankshaft journal bearings.
Crankshaft-journal-to-crank-
shaft-journal-bearing clear-
ance
0.004 ~ 0.028 mm
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
CAUTION:
ACHTUNG:
Do not interchange the crankshaft jour-
nal bearings. To obtain the correct
crankshaft-journal-to-crankshaft-jour-
nal-bearing clearance and prevent
engine damage, the crankshaft journal
bearings must be installed in their origi-
nal positions.
4 - 75
--- Page 25 ---
TRANSMISSION ENG
EB413100
REMOVING THE TRANSMISSION
1. Remove:
• main axle assembly 1
(with the Torx wrench T30)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Insert two bolts 2 of the proper size,
as shown in the illustration, into the
main axle assembly bearing housing.
b. Tighten the bolts until they contact
the crankcase surface.
c. Continue tightening the bolts until the
main axle assembly comes free from
the upper crankcase.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EB413400
CHECKING THE SHIFT FORKS
The following procedure applies to all of
the shift forks.
1. Check:
• shift fork cam follower 1
• shift fork pawl 2
Bends/damage/scoring/wear →
Replace the shift fork.
2. Check:
• shift fork guide bar
Roll the shift fork guide bar on a flat
surface.
Bends → Replace.
WARNING
WARNING
Do not attempt to straighten a bent
shift fork guide bar.
4 - 85
--- Page 26 ---
RADIATOR COOL
EB500020
INSTALLING THE RADIATOR
1. Fill:
• cooling system
(with the specified amount of the rec-
ommended coolant)
Refer to “CHANGING THE COOLANT”
in chapter 3.
2. Check:
• cooling system
Leaks → Repair or replace any faulty
part.
3. Measure:
• radiator cap opening pressure
Below the specified pressure →
Replace the radiator cap.
Refer to “CHECKING THE RADIATOR”.
5-4
--- Page 27 ---
WATER PUMP COOL
Order Job/Part Q’ty Remarks
5 Water pump seal 1
6 Oil seal 1
7 Bearing 1