MOTORCYCLE 12/4/2015 M2015-013R

Ue

©2015 YAMAHA MOTOR CORPORATION, U.S.A. i T NI

SA FET This modification has top priority. This bulletin must be performed
immediately to ensure customer safety. ;

FR a CA [ | NOTE: Bulletins that announce a recall will have an “R” at the end of the bulletin number.

ALL 2015 YZF-R1AND YZF-R1M MODELS
FACTORY MODIFICATION CAMPAIGN — Transmission Gears

Vv
] INTRODUCTION

Yamaha Motor Corporation, U.S.A. has decided
that a defect which relates to motor vehicle safety
exists in all 2015 YZF-R1 and YZF-R1M motor-
cycles. In affected motorcycles, both second gear
wheel and pinion gears in the transmission may
break as a result of extremely high stress and/or
improper shifting. This is due to inadequate compo-
nent strength and stress concentration at the gear
teeth bottom land. In addition, the third and fourth
wheel gears may be deformed or break as a result
of excessive stress caused by hard usage. This is
due to inadequate component strength. If gears fail,

the transmission could lock up, causing loss of con- _ —
trol that could result in a crash with injury or death. 2nd Gear 3rd Gear 4th Gear

To correct this defect, Yamaha is initiating a Factory
Modification Campaign. Affected units must have
the transmission assembly replaced with one that
includes gears of a different design.

Yamaha is notifying all registered owners of affected motorcycles by mail. A copy of this letter is included in
this bulletin. The customer should take this letter along with the affected motorcycle to an authorized Yamaha
dealer for modification.

If your dealership was invoiced one or more affected units, a computer report listing all affected motorcycles
invoiced to your dealership is included with this bulletin. Use the list to help ensure all motorcycles are modi-
fied. All sold motorcycles that have been registered with Yamaha will show the customer’s name and address.

Your dealership must notify the owner of any affected motorcycle that was actually sold but listed as “unsold”
in the report. You must modify all affected motorcycles in your inventory as well as all customer-owned motor-
cycles brought to you for this service. Any affected motorcycle that you purchase from Yamaha in the future
may also require modification. If you purchase a motorcycle from another dealer or Yamaha, check to see if
the procedures in this bulletin have already been performed before you sell the motorcycle.

Motorcycles that are affected should not be operated until they are modified. It is a violation of Yamaha policy
for your dealership to deliver any affected motorcycle to customers until the procedures in this bulletin are
performed.

When the modification on each motorcycle is performed, follow the Warranty Information section of this bul-
letin to receive reimbursement. Be sure to use the Factory Modification Campaign procedures in Chapter 7 of
the Warranty and Y.E.S. Handbook (LIT-11760-00-08).

PAGE 1 of 18

Q

=e DEALER ACTION SUMMARY

Unsold

and Sold

Units: Using Unit Status on YDS, check to be sure the unit is in the affected range and is unmodi-
fied. If so, replace the transmission gears and related components with those in the YZF-R1
Transmission Kit as described in this bulletin.

Parts: Yes. Order a YZF-R1 Transmission Kit for each affected unit that comes in for this modification.

You will also need Yamalube® Full Synthetic 15W-50 engine oil and Yamacool® High Performance
Antifreeze, or an equivalent.

Warranty: Factory Modification Campaign. See the Warranty Information section of this bulletin. This modi-
fication applies to all affected units regardless of ownership or warranty status.

Notify

Customers: Yes, you must immediately contact any customer whose motorcycle shows as unregistered on
the enclosed report. Yamaha has sent letters to customers whose motorcycles were registered
with Yamaha as of 12/03/2015.

Gr AFFECTED RANGE

All 2015 YZFR1IMF
All 2015 YZFR1MFC
All 2015 YZF-R1F
All 2015 YZF-R1FC

Q SERVICE PROCEDURES

NOTE: These procedures are meant to be used in
conjunction with the Service Manual (LIT-11616-28-
52) to complete this modification. Read and under-
stand these instructions completely prior to beginning
work on the unit. You must replace the engine oil using
Yamalube® Full Synthetic 15W-50 (P/N: LUB-15W50-
FS-12) and also replace the coolant, using Yamacool®
High Performance Antifreeze, or an equivalent, as
part of the modification on this engine.

ENGINE REMOVAL

1. Remove the rider’s seat, fuel tank, and both side
cowlings from the motorcycle. When removing the
plastic tray holding the ECU on the left hand side,
there is a bolt hidden behind the ECU itself. It is
also advisable to remove or cover the front fender
at this point to prevent damage while disassem-
bling the unit.

TIP:

The plastic console panels to the left and right of the
meter do not need to be removed. However, there is a
plastic dart on either panel that needs to be lifted from
the side panels prior to removal.

2. Disconnect the negative battery cable.

3. At the starter relay (solenoid), located near the
battery, disconnect the primary lead that goes
from the relay to the starter motor.

PAGE 2 of 18

4. With the engine at room temperature, remove the
radiator cap then remove the coolant drain bolt
located at the water pump.

TIP:
Removing the lower heat shields from the exhaust
before draining the coolant will help reduce spillage.

5. Remove the engine oil drain bolt and drain the oil.
Remove the oil filter.

6. Disconnect the oil lines from the oil cooler and
remove the oil cooler assembly.

7. Disconnect the EXUP cables from the exhaust.

Note that the black colored cable end is on the

top and the silver cable end is the bottom for re-

© assembly. Next, remove the exhaust system from
the headers back.

8. Remove the oil cooler bracket and water pipe
mounting bolt from the crankcase.

PAGE 3 of 18
10.

11.

12.

13.

14.

15.

Disconnect the cooling pipe from the water pump
by removing the retaining bolt. Remove the small
diameter hose from the top right of the radiator
taking care to not bend the radiator fitting.
Disconnect the clutch cable at the cable-retaining
bracket and detach the cable from the engine.

Disconnect the hose from the radiator on the left
side of the unit by removing the clamp from the
hose. Discard this clamp, it will not be reused.

Unplug all of the electrical connectors on the up-
per left side of the radiator located on the plastic
rectifier bracket, then remove the 2 bolts retaining
the rectifier bracket to the radiator.

Remove the radiator from the unit, being careful
to not scratch the front fender.

Disconnect the secondary injector wiring cou-
plers and fuel line from the air box and remove
the air box lid and air filter.

Depress the YCC-I (intake) funnels and remove
the 6 allen head bolts that attach the air box to the
throttle bodies. Unplug the YCC-I servo coupler,
crankcase breather hose, and AIS hose. Remove
the air box.

Disconnect the electrical connectors and the vac-
uum hose from the throttle bodies. Using an allen
socket with extension, loosen the 4 clamps that
secure the throttle bodies to the intake manifolds
by inserting the tool from below the frame on ei-
ther side.

TIP:

Removing the throttle cables is not necessary. Once
the throttle bodies are removed, there is enough
space to rotate the throttle bodies to the side. Use a
towel or tank protector to prevent scratching of com-
ponents where the throttle bodies are placed.

PAGE 4 of 18

16. Remove the ignition coils and AIS assembly from
the valve cover.

17. Disconnect all electrical connections below the
fuel tank area/top of the engine. Pay close at-
tention to verify all of the connectors were dis-
connected to prevent damage to sensors when
removing the engine. The coolant temperature
sensor (back of the cylinder head) and the gear
position sensor (top of crankcase above counter-
shaft sprocket area) are particularly easy to over-
look. Remove the starter motor cable that was
disconnected in step 3 from the tail area and set
the excess wire on top of the engine.

TIP:
On the YZF-R1M model, it is not necessary to unplug
the 2 connectors for the rear shock.

18. On the left side of the unit, unplug the electrical
connections for the stator, oil pressure sensor,
and QSS shift switch located inside of the black
rubber boot. Remove the shifter from the end of
the shift shaft splines, and remove the side stand
assembly. Next remove the countershaft sprock-
et cover and countershaft sprocket. If needed,
loosen the rear axle and adjust the drive chain to
gain additional chain slack to aid in removing the
countershaft sprocket from the engine.

IMPORTANT: Prepare a safe area to place the en-
gine after removal. Use a large piece of cardboard
or other soft material where the engine is placed to
prevent damage to the engine covers (the engine will
be oriented upside down on the work surface).

19. Place a suitable jack or stand under the engine.
When lowering the engine from the frame, it is
best to use 2 people. Remove the 2 upper engine
mounting bolts, then remove the nuts from the 2
rear engine mounis. Retract the 2 rear bolts that
secure the engine to the frame and loosen the
2 collars inside the frame using the special tool
(KM-01485, available from K&L Supply). Lower
the engine from the chassis carefully while check-
ing for wiring connections or hoses that may have
been overlooked in earlier steps. It may be nec-
essary to rotate the engine slightly so the drive
chain is free of the transmission counter shaft.
When the engine is removed, place the engine
upside down on the prepared work surface.

NOTE: The adjacent photo shows the engine cor-
rectly positioned after removal. The remainder of this
procedure can be performed with the engine in this
position.

PAGE 5 of 18

ENGINE

NOTICE:

The YZF-R1 and YZF-R1M are equipped with mag-
nesium engine covers with aluminum hardware.
Scratches to any of the engine covers will require
touch-up or replacement. The aluminum bolts
used on the engine covers are one time use only.
Do not attempt to reuse any of these bolts. Use
a torque wrench following the proper procedures
outlined in the service manual to install this hard-
ware.

20. Remove the generator cover from the left side of
the engine and discard the bolts. It is NOT neces-
sary to remove the flywheel.

21. Remove the timing cover from the right side of the
engine and discard the bolts. Make sure to rein-
stall the cam chain tensioner guide pivots if they
come off with the engine cover.

PAGE 6 of 18

22. Remove the oil pipes, water pump, and coolant
pipe.

23. Remove the oil strainer cover (oil pan) and dis-
card the mounting hardware.

TIP:

Loosen each bolt 1/4 of a turn at a time, in stages,
and in a crisscross pattern. After all the bolts are fully
loosened, remove them.

PAGE 7 of 18
24. On the right side of the engine, remove the clutch
cover and discard the mounting hardware. Next,
remove the 3 bolts that secure the clutch springs
and remove the clutch plates.

TIP:

Make note of the order of the plates. The outer 3
plates (2 fiber and 1 steel) and innermost fiber plate
are different.

25. Using a clutch holder and appropriate hand tools
(breaker bar), loosen then remove the clutch hub
nut.

NOTICE:

Do NOT use power tools to disassemble the
clutch, damage will result.

Remove the remainder of the clutch assembly.
A universal clutch holder (shown in the adjacent