2017 Yamaha YZF-R3 Service & Repair Manual

._ ·; YAMAHA YZF-R3 Service Manual

EAS20003 IMPORTANT This manual was produced by the Yamaha Motor Corporation, U.S.A. primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles should have a basic understanding of mechanics and the techniques to repair these types of vehicles. Repair and maintenance work attempted by anyone without this knowledge is likely to render the vehicle unsafe and unfit for use. Yamaha Motor Corporation, U.S.A. is continually striving to improve all of its models. Modifications and significant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will appear in future editions of this manual where applicable. TIP~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~ Designs and specifications are subject to change without notice. EAS30001 IMPORTANT MANUAL INFORMATION Particularly important information is distinguished in this manual by the following notations. A WARNING 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. A NOTICE indicates special precautions that must be taken to avoid damage to the vehicle or other property. A TIP provides key information to make procedures easier or clearer.

EAS20004 HOW TO USE THIS MANUAL This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid out with the individual steps in sequential order. •The manual is divided into chapters and each chapter is divided into sections. The current section title "1" is shown at the top of each page. • Sub-section titles "2" appear in smaller print than the section title. •To help identify parts and clarify procedure steps, there are exploded diagrams "3" at the start of each removal and disassembly section. • Numbers "4" are given in the order of the jobs in the exploded diagram. A number indicates a disassembly step. • Symbols "5" indicate parts to be lubricated or replaced. Refer to "SYMBOLS". • A job instruction chart "6'' accompanies the exploded diagram, providing the order of jobs, names of parts, notes in jobs, etc. This step explains removal and disassembly procedure only. For installation and assembly procedure, reverse the steps. • Jobs "7" requiring more information (such as special tools and technical data) are described sequen- tially. 1 VALVES AND VALVE SPRINGS VALVES AND VALVE SPRINGS Removi ng the valves and valve springs 3-+------ 4-+-- +---- -- 5-+---+-t~ 6 Cyhnderhtlad Reier to "CVUNOER HEAD. 0t1 oaoe S.22 Valvo pad I a I ' Vatve9J)11n9 5eat 10 vatve g~ 5-28 2. Measure: • Compressed valve spring force "a~ Out of specification - Replace the valve spring. Installed compression spring force (i ntake) 159.6<>-183.60 N (16.27- 18.72 kgl, 35.88-41 .27 lbl) Installed compression spring force (exhausl) 159.6<>-183.60 N (16.27- 18.72 kgl, 35.88-41 .27 lbl) Installed lenglh (Intake) 30.90 mm (1.22 in) Installed length (exhaust) 30.90 mm (1.22 in) b. lnslalled length 3. Measure: • Valve spring lilt ~a· Out of specilication --+ Replace the valve spnng Spring tilt (I ntake) 1.6 mm (0.06 in) Spring tilt (exhaust) 1.6 mm (0.06 In) VALVES AND VALVE SPRINGS 5-33 ~1~1~~~9~~~:~,~~:;;,~;~sa .... 11 ol l- the ----t-2 valve litters 1. Check: •Valve titter Damage/scratches --+ Replace the valve lift- ers and cylinder head mrALLING THE VALVES The following procedure applies to all of the 'Valves and related componen1s. 1. Deburr: • Valvestem end (wilh an oil stone) 2. Lubricate· • Valve stem ~,- • Valve stem end (wi th the recommended lubricant) ~ Recommended lubricant Molybdenum dlsu111de oil 3. lubricate • Valvestem seal"2- (with the recommended lubricant) ..._. Recommended lubricant Engine oU 7

EAS20005 SYMBOLS The following symbols are used in this manual for easier understanding. TIP~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~ The following symbols are not relevant to every vehicle. SYMBOL DEFINITION SYMBOL DEFINITION ~ Serviceable with engine mounted 1 Gear oil ~ ~ Filling fluid 1 Molybdenum disulfide oil ~ B Lubricant 1 Brake fluid ~ ~ Special tool ~ Wheel bearing grease 1 ~~ 1 Tightening torque ~ Lithium-soap-based grease ~ Wear limit, clearance -cM»t Molybdenum disulfide grease [g Engine speed -c§»I Silicone grease [i]jJ ' Electrical data tLTi Apply locking agent (LOCTITE®). 1 l~ml m Engine oil Replace the part with a new one. 1 Silicone fluid m

,,,,_ TABLE OF CONTENTS GENERAL INFORMATION SPECIFICATIONS PERIODIC CHECKS AND ADJUSTMENTS CHASSIS ENGINE COOLING SYSTEM FUEL SYSTEM ELECTRICAL SYSTEM TROUBLESHOOTING

GENERAL INFORMATION IDENTIFICATION ............................................................................................ 1-1 VEHICLE IDENTIFICATION NUMBER ..................................................... 1-1 MODEL LABEL .......................................................................................... 1-1 FEATURES ...................................................................................................... 1-2 OUTLINE OF THE Fl SYSTEM ................................................................. 1-2 Fl SYSTEM ................................................................................................ 1-3 MUL Tl-FUNCTION METER UNIT ............................................................. 1-4 IMPORTANT INFORMATION ......................................................................... 1-9 PREPARATION FOR REMOVAL AND DISASSEMBLY ........................... 1-9 REPLACEMENT PARTS ........................................................................... 1-9 GASKETS, OIL SEALS AND 0-RINGS .................................................... 1-9 LOCK WASHERS/PLATES AND COTTER PINS ..................................... 1-9 BEARINGS AND OIL SEALS .................................................................. 1-10 CIRCLIPS ................................................................................................ 1-10 RUBBER PARTS ..................................................................................... 1-10 BASIC SERVICE INFORMATION ................................................................. 1-11 QUICK FASTENERS ............................................................................... 1-11 ELECTRICAL SYSTEM ........................................................................... 1-12 SPECIAL TOOLS .......................................................................................... 1-17

EAS20007 IDENTIFICATION EAS30002 VEHICLE IDENTIFICATION NUMBER The vehicle identification number "1" is stamped into the frame under the passenger seat. EAS30003 MODEL LABEL The model label "1" is affixed to the frame under the passenger seat. This information will be needed to order spare parts. IDENTIFICATION 1-1

FEATURES EAS20008 FEATURES EAS30005 OUTLINE OF THE Fl SYSTEM The main function of a fuel supply system is to provide fuel to the combustion chamber at the optimum air-fuel ratio in accordance with the engine operating conditions and the atmospheric temperature. In the conventional carburetor system, the air-fuel ratio of the mixture that is supplied to the combustion chamber is created by the volume of the intake air and the fuel that is metered by the jet used in the respective carburetor. Despite the same volume of intake air, the fuel volume requirement varies by the engine operating conditions, such as acceleration, deceleration, or operating under a heavy load. Carburetors that meter the fuel through the use of jets have been provided with various auxiliary devices, so that an optimum air- fuel ratio can be achieved to accommodate the constant changes in the operating conditions of the engine. As the requirements for the engine to deliver more performance and cleaner exhaust gases increase, it becomes necessary to control the air-fuel ratio in a more precise and finely tuned manner. To accommodate this need, this model has adopted an electronically controlled fuel injection (Fl) system, in place of the conventional carburetor system. This system can achieve an optimum air-fuel ratio required by the engine at all times by using a microprocessor that regulates the fuel injection volume according to the engine operating conditions detected by various sensors. The adoption of the Fl system has resulted in a highly precise fuel supply, improved engine response, better fuel economy, and reduced exhaust emissions. 16 15 14 13 12 11 10 9 1. Engine trouble warning light 1 O. ISC (idle speed control) unit 2. Ignition coils 11. Throttle body sensor assembly 3. Air induction system solenoid 12. 0 2 sensor 4. Coolant temperature sensor 13. Sidestand switch 5. Fuel pump 14. Crankshaft position sensor 6. Battery 15. Speed sensor 7. ECU (engine control unit) 16. Spark plugs 8. Lean angle sensor 9. Fuel injectors 1-2

2017 Yamaha YZF-R3 Service & Repair Manual

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