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62-563: Yamaha launched the YZF-R1 in 1998 after redesigning the Genesis engine to create a more compact engine by raising the gearbox input shaft and allowing the gearbox output shaft to be placed beneath it. This "stacked gearbox" was followed by other manufacturers. Compacting the engine made it much shorter, allowing the wheelbase to be shortened as well and the center of gravity to be optimized. The swingarm could be made longer without compromising

124-459: A CV carburetor slide controlled by a vacuum created by the engine. With a similar power output to the 2000-2001 bike, though, the engine remained largely the same. One notable improvement was the use of new cylinder sleeves of a high silicon content alloy containing magnesium that minimized thermal distortion, reducing oil consumption. The exhaust system was changed from a 4-into-1 to a new titanium 4-into-2-into-1 design. Also in 2002, Yamaha released

186-416: A draw ring and punch (metalworking) or male die is required. Depending on the part being formed, the punch can be made from epoxy, rather than metal. The bladder of the hydroform itself acts as the female die eliminating the need to fabricate it. This allows for changes in material thickness to be made with usually no necessary changes to the tool. However, dies must be highly polished and in tube hydroforming

248-409: A female solid die. In hydro-mechanical deep drawing, a work piece is placed on a draw ring (blank holder) over a male punch then a hydraulic chamber surrounds the work piece and a relatively low initial pressure seats the work piece against the punch. The punch then is raised into the hydraulic chamber and pressure is increased to as high as 100 MPa (15000 psi) which forms the part around the punch. Then

310-498: A high-power and high-torque engine. The Yamaha YZF-R6 was introduced in 1999 as the 600 cc version of the R1 super bike. The 1999 R1 saw only minor changes, apart from paint and graphics. Improvements included a redesigned gear change linkage and an increase in gear change shaft length. Fuel tank reserve capacity was reduced from 5.5 to 4.0 L (1.21 to 0.88 imp gal; 1.5 to 1.1 US gal), while total fuel tank capacity

372-427: A hydroforming process must take into consideration the initial tube material properties and its potential for variation, along with the bending process, hydraulic pressure throughout the forming process, in inclusion of axial feed or not, in order to predict metal formability. Tools and punches can be interchanged for different part requirements. One advantage of hydroforming is the savings on tools. For sheet metal only

434-399: A larger rear 200/55 size. Starting in 2016, the lower-spec R1S model has also been offered. At EICMA 2017 Yamaha presented the next generation of R1 and R1M. They have a better Quick Shift System, an updated Lift (wheelie) Control System and fulfill Euro 4 requirements. The R1M got a new Öhlins Electronic Racing Suspension. In 2019 next new models started. The R1 achieved five victories in

496-488: A multivalve engine, maximum RPM is limited by the size of the largest valves: in a 3-valver, the exhaust valve is larger, and in a 4-valver, the inlet valves are larger. The significance of the five-valve engine compared to other multivalve configurations engines is that, like a 3-valver, there were more intake valves than exhaust valves, yet all valves were small and of very similar sizes and weights. Downdraft carburetors were adopted for improved gas flow, but, for motorcycles,

558-441: A new generation of R1, similar to the contemporary YZR M1. Yamaha claims a wet weight of 199 kg (439 lb). Engine changes include a decreased bore-to-stroke ratio , a larger airbox , a finger-follower valve system, and fracture split titanium conrods . Magnesium wheels are standard, and information is presented to the rider through a user-customizable thin-film display. The new bike has an electronics package that includes

620-408: A perceived disadvantage was that the intake airbox was above the engine, taking up space from the fuel tank, rather than being sited conventionally behind the engine. However, this apparent disadvantage was an advantage as it allowed for pressurization of the airbox. Also, Yamaha dealt with this apparent loss of fuel tank volume by building the tank lower and using an electric fuel pump to pump fuel to

682-438: A pressure would be required. in fact, the die closing force can be very high, both in tube and sheet hydroforming and may easily overcome the maximum tonnage of the forming press. In order to keep the die closing force under prescribed limits, the maximum internal fluid pressure must be limited. This reduces the calibration abilities of the process, i.e. it reduces the possibility of forming parts with small concave radii. Limits of

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744-505: A quarter-mile time of 9.90 seconds at 144.98 mph (233.32 km/h), and a top speed of 189 mph (304 km/h). The R1's swingarm was extended by 20 mm (0.79 in) to reduce instability during acceleration. That year, Yamaha also released a limited edition version, the LE, in original Yamaha racing colors to celebrate its 50th anniversary. The LE and SP models had custom Öhlins front and rear suspension units developed by

806-497: A second. Power delivery is tapered through throttle valve manipulation and ignition and fuel cuts. A second higher-spec, limited production model called the R1M is also produced, and is differentiated from the standard model by having more expensive components, such as electronic semi-active Öhlins suspension, carbon fiber bodywork, Yamaha's Communication Control Unit (CCU), a Y-TRAC data logging system, and grippier Bridgestone tires with

868-423: A sophisticated Traction Control System (TCS), a Slide Control System (SCS), an anti-wheelie Lift Control System (LIF), linked antilock brakes , a Launch Control System (LCS), a Quick Shift System (QSS), and selectable power modes. The Slide Control System on the R1 is the first on a production motorcycle. Information is fed to the bike through a six-axis inertial measurement unit and other sensors over 100 times

930-409: A taller first gear, a hollow chrome-moly gear change shaft with an additional bearing, and a completely redesigned shift linkage and foot pedal. These changes were aimed at eliminating problems with the transmission in earlier models, and to help seamlessly transfer the bike's power to the road. A new fuel injection system was introduced for the 2002 year, which worked like a carburetor by employing

992-617: A tested top speed of 176.7 mph (284.4 km/h). In 2012, the Yamaha YZF-R1 received traction control and a redesigned nose, and a special edition 50th Anniversary R1 was released. The special edition commemorates the participation of Yamaha in MotoGP, and its colours are inspired by the Assen TT -winning MotoGP bike. Only 2000 units of this edition were made. At the centennial EICMA motorcycle show, Yamaha officially unveiled

1054-465: A top speed of 167 mph (269 km/h). For 2003, the only change was the addition of hazard warning lights and low-beam headlights, which stay on when the engine is running. With the competition advancing, Yamaha made some major changes to the R1. This included style updates, like an underseat dual exhaust, and performance upgrades including radial brakes, and, for the first time, a ram-air intake . Furthermore, earlier models' tendency for wheelies

1116-444: A topic of discussion for sheet metal forming operations it has been far less of a topic of research for tube hydroforming. This may in part be a result of the relatively low levels of springback naturally occurring when deforming the tubes into their closed section geometries. Tube Hydroformed sections by the nature of their closed sections are very rigid and do not display high degrees of elastic deformation under load. For this reason it

1178-502: A two-piece die is required to allow opening and closing. Another advantage of hydroforming is that complex shapes can be made in one step. In sheet hydroforming with the bladder acting as the male die almost limitless geometries can be produced. However, the process is limited by the very high closing force required in order to seal the dies, especially for large panels and thick hard materials. Small concave corner radii are difficult to be completely calibrated, i.e. filled, because too large

1240-403: A wider radiator, and M1 styling on the new large ram-air intakes in the front fairing. There were no major changes for 2008. Power at the rear wheel was 156.7 hp (116.9 kW) @ 10,160 rpm. Motorcycle Consumer News tests of the 2007 model year YZF-R1 yielded a 0 to 60 mph (0 to 97 km/h) time of 2.94 seconds and 0 to 100 mph (0 to 161 km/h) of 5.46 seconds,

1302-550: A ¼ mile time of 9.88 seconds at 145.50 mph (234.16 km/h). In late 2008, Yamaha announced they would release an all new R1 for 2009. The new R1 took engine technology from the M1 MotoGP bike with its crossplane crankshaft , making the 2009 R1 the first production sports bike to use a crossplane crankshaft. Power delivery is the same as with a 90° V4 with a 180° crank (such as the Honda VFR800 , and similar to

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1364-441: Is a bladder that contains the liquid; no liquid contacts the sheet) and hydroforming where the fluid contacts the sheet (no bladder). Bladder forming is sometimes called flexforming. Flexforming is mostly used for low volume productions, as in the aerospace field. Forming with the fluid in direct contact with the part can be done either with a male solid punch (this version is sometimes called hydro-mechanical deep drawing ) or with

1426-432: Is a specialized type of die forming that uses a high pressure hydraulic fluid to press room temperature working material into a die. To hydroform aluminium into a vehicle's frame rail, a hollow tube of aluminium is placed inside a negative mold that has the shape of the desired result. High pressure hydraulic pumps then inject fluid at very high pressure inside the aluminium tube which causes it to expand until it matches

1488-439: Is applied to the inside of a tube that is held by dies with the desired cross sections and forms. When the dies are closed, the tube ends are sealed by axial punches and the tube is filled with hydraulic fluid . The internal pressure can go up to a few thousand bars and it causes the tube to calibrate against the dies. The fluid is injected into the tube through one of the two axial punches. Axial punches are movable and their action

1550-441: Is controlled by the rider through a forward mode button near the throttle. The instrument panel was more comprehensive than previous models, and the 2009/2010 Yamaha YZF-R1 model had a gear indicator as standard. Overall handling of the R1 was improved through changes to frame and suspension. A new cast magnesium subframe was designed for the 2009 R1, resulting in lower weight and aiding mass centralisation. The rear shock absorber on

1612-460: Is mostly used in the automotive sector, where many industrial applications can be found. With the rise of the electric bicycle it is now a method of choice for e-bicycle manufacturers. Especially down tubes and top tubes are favorably made with hydroforming in order to fit the battery for the electric bicycle. Newest applications in the bicycle industry are now hydroformed handlebars to improve aero dynamics and ergonomics. In tube hydroforming pressure

1674-448: Is possible only for limited cases. Advances in FEA and FEM in recent years has enabled hydroform processes to be more widely engineered for varieties of parts and materials. Often FEM simulations must be performed in order to find a feasible process solution and to define the correct loading curves: pressure vs. time and axial feed vs. time. In the case of more complex tube hydroformed parts

1736-447: Is required to provide axial compression and to feed material towards the center of the bulging tube. Transverse counterpunches may also be incorporated in the forming die in order to form protrusions with small diameter/length ratio. Transverse counter punches may also be used to punch holes in the work piece at the end of the forming process. Designing the process has in the past been a challenging task, since initial analytical modeling

1798-482: The 2009 Superbike World Championship season title, recording 14 wins and 11 poles in his one season in WSBK. Pata Yamaha World Superbike rider Toprak Razgatlıoğlu won the 2021 Superbike World Championship, recording 13 wins and 3 Superpoles. The Yamaha Factory Racing Team with riders N. Nakasuga, P. Espargaro, and B. Smith won the 2015 Suzuka 8 Hours endurance race. Katsuyuki Nakasuga, Alex Lowes and Pol Espargaro won

1860-555: The Macau Grand Prix between 1999 and 2013. Lorenzo Alfonsi won the 2004 FIM Superstock 1000 Cup , followed by Didier Van Keymeulen in 2005. Yamaha World Superbike riders Troy Corser and Noriyuki Haga finished 2nd and 3rd respectively in the 2008 Superbike World Championship season . John McGuinness won the Senior and inaugural Superbike races at the 2005 Isle of Man TT . Yamaha World Superbike rider Ben Spies won

1922-401: The drag coefficient was achieved. The headlight housing's profile was sharpened, the side panels were made more aerodynamic, and the windscreen was reshaped for better rider protection. The seating area was also updated. The fuel tank was reshaped, with a more relaxed rear angle and deeper leg recesses to provide a better riding feel. The seat extended further towards the rear of the tank, and

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1984-452: The 1999 model year, Cycle World tests recorded a 0 to 60 mph (0 to 97 km/h) time of 3.0 seconds, 0 to 1 ⁄ 4  mi (0.00 to 0.40 km) time of 10.31 seconds at 139.55 mph (224.58 km/h), and a top speed of 170 mph (270 km/h). In 2000, Yamaha introduced a series of changes to improve the R1, and minor changes to the bodywork to allow for better long-duration ride handling. Yamaha's main design goal

2046-596: The 2007 model year was announced on 8 October 2006. It had an all-new inline-four engine, going back to a more conventional four-valve-per-cylinder design rather than Yamaha's trademark five-valve Genesis layout. It also had the Yamaha Chip Control Intake (YCC-I) electronic variable-length intake funnel system, Yamaha Chip Control Throttle (YCC-T) fly-by-wire throttle system, slipper clutch, all-new aluminum Deltabox frame and swingarm, six-piston radial-mount front brake calipers with 310 mm discs,

2108-517: The 2009 model. This new design used only projector lamps in the headlights and used the newfound design space on the nose to position ram-air intakes next to the lights. Testing the 2010 model on a tri-oval racetrack, Motorcyclist magazine reported a 0 to 1 ⁄ 4  mi (0.00 to 0.40 km) time of 10.02 seconds @ 144.23 mph (232.12 km/h), and fuel consumption of 25 mpg ‑US (9.4 L/100 km; 30 mpg ‑imp ). Motorcycle Consumer News reported

2170-399: The 2009 offers variable speed damping, as well as easy-to-tweak screw-adjustable preload. The rear shock absorber connected underneath the swing arm via a linkage, a change from previous models. To improve overall handling and safety, Yamaha included an electronic steering damper. The front had the same classic R1 design cues, though the air-intake location and headlamp design were revamped on

2232-536: The 2016 Suzuka 8 Hours race. Katsuyuki Nakasuga , Alex Lowes , Michael van der Mark won the 2017 and 2018 Suzuka 8 Hours races. Tommy Hill won the British Superbike title in 2011 on board a YZF-R1. Yamaha rider Josh Brookes won the 2015 title. Yamaha Genesis engine "Genesis" is Yamaha's marketing name for a range of innovative, high-performance multi-valve four-stroke motorcycle engines . The flexible design of

2294-493: The 65° V4 in the Yamaha V-Max ). Yamaha claimed the bike would give the rider "two engines in one", with the low-end torque of a twin and the pace of an inline-four. As with the previous incarnation of the R1, the 2009 model used Yamaha Chip Control Throttle (YCC-T). Another advancement included in the 2009 model was D-Mode Throttle Control Valve Mapping, which allows a rider to choose between three distinct maps depending on

2356-672: The bank of carburetors above. A deeper fuel tank also gave a small advantage as it centralized weight and moved the CoG lower. What could be argued is that the Genesis concept (not just the inclination of the engine, although on the FZ750 was a radical 45 degrees, on the FZR1000 a less radical 35 degrees, a feature now generally universally used in the modern (post 1990) sport bike thus allowing downdraft air induction and airbox pressurization, but also

2418-604: The cylinder block slanted forwards 45 degrees. The Genesis engine was also used in the Yamaha YZF-R1 , FZX700, FZ750, and the USA-only FZ700. Other applications ranged from the Supersport YZF-R6 and YZF-R1 models, using electronic fuel injection with YCCT and YCCI, to the less extreme but still powerful Yamaha FZ6 (4 valve per cylinder) and FZ1 Fazer line, which had a simpler fuel injection design but

2480-495: The engine allowed Yamaha to use it on a variety of configurations, from sport bikes to outboard engines. The DOHC Genesis engine has five valves per cylinder and downdraft carburetors . Yamaha adopted the 5-valve concept, using three intake valves and two exhaust valves per cylinder, because it allowed both excellent volumetric efficiency and high RPM. As designers began to appreciate the benefits of multi-valve layout, 4-valves-per-cylinder (and even 3-valves) became common. In

2542-596: The engine has also been employed in various other uses such as gyroplanes and high power marine engines, making it an affordable solution for high performance applications. The engine is also used in a racecar championship in Norway called SevenRacing. It is a copy of Lotus Super Seven, and is produced by MK and Stuart Taylor. Hydroforming Hydroforming is a means of shaping ductile metals such as aluminium , brass , low alloy steel , and stainless steel into lightweight, structurally stiff and strong pieces. One of

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2604-628: The fluid explosively in an arc to deform the working material. This process is based on the 1950s patent for hydramolding by Fred Leuthesser, Jr. and John Fox of the Schaible Company of Cincinnati, Ohio in the United States. It was originally used in producing kitchen spouts. This was done because in addition to the strengthening of the metal, hydromolding also produced less "grainy" parts, allowing for easier metal finishing. In sheet hydroforming there are bladder forming (where there

2666-433: The front turn signals and the repurposing of the parking lights as directional or hazard markers while stopped. In 2002, Cycle World reported fuel mileage of 38 mpg ‑US (6.2 L/100 km; 46 mpg ‑imp ), a 0 to 60 mph (0 to 97 km/h) time of 2.9 seconds, a 0 to 1 ⁄ 4  mi (0.00 to 0.40 km) time of 10.32 seconds at 137.60 mph (221.45 km/h), and

2728-478: The high pressure process the tube is fully enclosed in a die prior to pressurization of the tube. In low pressure the tube is slightly pressurized to a fixed volume during the closing of the die (this used to be called the Variform process). Historically, the process was patented in the '50s, but it was industrially spread in the 1970s for the production of large T-shaped joints for the oil and gas industry. Today it

2790-411: The largest applications of cost-effective hydroforming is the automotive industry, which makes use of the complex shapes made possible by hydroforming to produce stronger, lighter, and more rigid unibody structures for vehicles. This technique is particularly popular with the high-end sports car industry and is also frequently employed in the shaping of aluminium tubes for bicycle frames. Hydroforming

2852-461: The maximum closing force is seldom a limiting factor in tube hydroforming. Hydroforming is capable of producing parts within tight tolerances including aircraft tolerances where a common tolerance for sheet metal parts is within 0.76 mm (1/30th of an inch). Metal hydroforming also allows for a smoother finish as draw marks produced by the traditional method of pressing a male and female die together are eliminated. While springback has long been

2914-588: The mold. The hydroformed aluminium is then removed from the mold. Hydroforming allows complex shapes with concavities to be formed, which would be difficult or impossible with standard solid die stamping . Hydroformed parts can often be made with a higher stiffness-to-weight ratio and at a lower per unit cost than traditional stamped or stamped and welded parts. Virtually all metals capable of cold forming can be hydroformed, including aluminium, brass, carbon and stainless steel, copper, and high strength alloys. Electrohydraulic forming uses electrodes to vaporize

2976-568: The new steeper seating position put additional weight on the front end. All of this was aimed at improving weight bias, thus offering sharper cornering and more stability. Mechanically, the carburetors were re-jetted in an effort to improve throttle response, especially in the low end, all the way up to the bike's 11,750 rpm redline . The redesigned camshafts were lightened and used internal oil ways to lubricate journals that, when combined with reduced tappet clearance, provided less friction and created less engine noise. The gearbox received

3038-449: The newly developed Deltabox frame, whose hydro-formed construction reduced the total number of frame welds and improved the frame's rigidity by 30%. The cooling system was redesigned for better performance and compactness. The rear end of the motorcycle was updated and streamlined with an LED taillight, allowing for cleaner rear body lines when choosing one of several common aftermarket modifications. These modifications included removal of

3100-563: The overall wheelbase, which was a short 1,385 mm (54.5 in). Four 40 mm Keihin CV carburetors fed fuel to the engine. The R1 was also equipped with a 41 mm KYB upside-down front fork and 300 mm semi-floating disc brakes . The instrument panel was electronic, with a self-diagnosis system and digital speed readout. The exhaust used Yamaha's Exhaust Ultimate Power Valve (EXUP) system, which controlled exhaust gas flow to maximize engine power production at all revs, resulting in

3162-557: The pressure is released and punch retracted, hydraulic chamber lifted, and the process is complete. Among these techniques hydraulic bulge testing allows for an increased work hardening of sheet material by distinctive stretching operations and provides better shape accuracy for complex parts. Hence, by selecting proper material and the forming parameters for hydraulic sheet bulging study one can determine Forming Limit Curves (FLCs). [1] Significance In tube hydroforming there are two major practices: high pressure and low pressure . With

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3224-495: The rider's environment. Each mode of operation controls YCC-T characteristics, changing how the R1 reacts to rider input. The first mode is Standard Mode, which delivers performance for a wide variety of driving conditions. The second mode is "A" mode, which will give a rider more available power in the lower to mid RPM range. The third mode is "B" mode, a dialling back of the previous mode designed to soften throttle response in inclement weather and heavy traffic. D-Mode throttle control

3286-479: The same team as the YZR-M1 MotoGP bike. Custom forged aluminum Marchesini wheels specifically designed for the LE shaved nearly a pound off the bike's unsprung weight. A back torque-limiting slipper clutch and an integrated lap timer rounded out the package, essentially making the LE a production racer. Only 500 units were made for the United States, with another 500 units for Europe. An all-new YZF-R1 for

3348-421: The sheet hydroforming process are due to risks of excessive thinning, fracture, wrinkling and are strictly related to the material formability and to a proper selection of process parameters (e.g. hydraulic pressure vs. time curve). Tube hydroforming can produce many geometric options as well, reducing the need for tube welding operations. Similar limitations and risks can be listed as in sheet hydroforming; however,

3410-409: The tube must be pre-bent prior to loading into the hydroforming die. Bending is done sequentially along the length of the tube, with the tube being bent around bending discs (or dies) as the tube length is fed in. Bending can be done with or without mandrels. This additional complexity of process further increases the reliance on FEM for designing and evaluating manufacturing processes. The feasibility of

3472-402: The turn signal stalks and stock license plate bracket, and replacing them with replacements that "hugged" the body or frame. The 2002 model also saw front lighting improvements in the form of sharper headlights and the addition of side "parking" lights within the twin-headlight panel, giving a more angular appearance. This also provided additional aftermarket possibilities, such as the removal of

3534-512: The use of beam frames as opposed to spine or perimeter frames previously commonly used) set the architecture for the modern sport bike. The Genesis engine first appeared on the 1985 Yamaha FZ750 and was later used on a variety of motorcycles for different kinds of markets. The design was used for parallel-twins (such as the TDM and the TRX ) as well as for four-cylinder models. Both fours and twins had

3596-471: Was also added in 2004. Combined with the changes to the frame, this helped to eliminate the tendency of the handlebars to shake violently during rapid acceleration or deceleration on less-than-perfect surfaces, a phenomenon known as speed wobble or a tank slapper. Motorcycle Consumer News tests of the 2004 model year YZF-R1S yielded a 0 to 60 mph (0 to 97 km/h) time of 3.04 seconds and 0 to 100 mph (0 to 161 km/h) of 5.42 seconds,

3658-418: Was reduced by changing the geometry of the frame and weight distribution. The all-new engine was no longer used as a stressed member of the chassis, and had a separate top crankcase and cylinder block . The 2004 R1 weighs 172 kg (379 lb) dry. The conventional front brake calipers were replaced by radially mounted calipers, activated by a radial master cylinder. A factory-installed steering damper

3720-467: Was the same basic engine design. The most significant changes made were the 4-valve per cylinder configuration and the crossplane crankshaft found on the YZF-R1 in 2009, along with the change of cylinder sleeves to steel for high precision and high temperature durability. Throughout its long period of production, the Genesis range has successfully provided performance and reliability. Because of its high performance capacity (usually from 100 BHP - 350 BHP),

3782-415: Was to sharpen the pre-existing bike and not to redesign it. The dry weight was reduced five pounds to 414 lb (188 kg). At 127.8 hp (95.3 kW) at the rear wheel, top-end output remained the same, but changes to the engine management system were intended to result in a smoother, broader distribution of power. The bodywork remained similar to that of the previous R1, although a 3% reduction in

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3844-528: Was unchanged at 18 L (4.0 imp gal; 4.8 US gal). Motorcycle Consumer News tests of the 1998 model year YZF-R1 yielded a 0 to 60 mph (0 to 97 km/h) time of 2.96 seconds and 0 to 100 mph (0 to 161 km/h) of 5.93 seconds, a 0 to 1 ⁄ 4  mi (0.00 to 0.40 km) time of 10.19 seconds at 131.40 mph (211.47 km/h), and a top speed of 168 mph (270 km/h), with deceleration from 60 to 0 mph (97 to 0 km/h) of 113.9 ft (34.7 m). For

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