Yamaha YZF-R1 2004, Service Information

Page 1: ...Yamaha Motor Co Ltd 2004 YZF R1 S 5VY1 SE1 SERVICE INFORMATION ...

Page 2: ...ormation has been prepared to introduce new service and data for the YZF R1 S 2004 For complete service information procedures it is necessary to use this Service Information together with the following manual YZF R1 S 2004 SERVICE MANUAL 5VY1 ME1 ...

Page 3: ...mprove all of its models Modifications and sig nificant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will appear in future editions of this manual where applicable Designs and specifications are subject to change without notice EAS00004 IMPORTANT MANUAL INFORMATION Particularly important information is distinguished in this manual by the following ...

Page 4: ...trical system 9 Troubleshooting Symbols 10 to 17 indicate the following 10 Serviceable with engine mounted 11 Filling fluid 12 Lubricant 13 Special tool 14 Tightening torque 15 Wear limit clearance 16 Engine speed 17 Electrical data Symbols 18 to 23 in the exploded diagrams indi cate the types of lubricants and lubrication points 18 Engine oil 19 Gear oil 20 Molybdenum disulfide oil 21 Wheel beari...

Page 5: ...ONS 12 ELECTRICAL SPECIFICATIONS 16 CONVERSION TABLE 19 GENERAL TIGHTENING TORQUE SPECIFICATIONS 19 TIGHTENING TORQUES 20 ENGINE TIGHTENING TORQUES 20 CHASSIS TIGHTENING TORQUES 24 LUBRICATION POINTS AND LUBRICANT TYPES 26 ENGINE 26 CHASSIS 27 CABLE ROUTING 28 PERIODIC CHECKS AND ADJUSTMENTS INTRODUCTION 42 PERIODIC MAINTENANCE AND LUBRICATION INTERVALS 42 YZF R1 S 2004 WIRING DIAGRAM ...

Page 6: ...ORCYCLE IDENTIFICATION EAS00017 VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the right side of the steering head pipe EAS00018 MODEL LABEL The model label 1 is affixed to the frame This information will be needed to order spare parts 1 ...

Page 7: ...ngth Overall width Overall height Seat height Wheelbase Minimum ground clearance Minimum turning radius 2 065 mm 8 13 in 720 mm 28 3 in 1 105 mm 43 5 in 835 mm 32 9 in 1 395 mm 54 9 in 135 mm 5 31 in 3 400 mm 133 9 in SSS SSS SSS SSS SSS SSS SSS Weight Wet with oil and a full fuel tank Maximum load except motorcycle 193 kg 425 lb 202 kg 445 lb SSS SSS 2 ...

Page 8: ...fuel Fuel tank capacity Total including reserve Reserve only Premium unleaded gasoline only 18 L 3 96 Imp gal 4 76 US gal 3 4 L 0 75 Imp gal 0 90 US gal SSS SSS SSS Engine oil Lubrication system Recommended oil Quantity Total amount Without oil filter cartridge replacement With oil filter cartridge replacement Oil pressure Engine oil temperature Relief valve opening pressure Wet sump SAE 20W40 SE ...

Page 9: ...p opening pressure Radiator core Width Height Depth Coolant reservoir Capacity Water pump Water pump type Reduction ratio Max impeller shaft tilt 2 51 L 2 21 Imp qt 2 65 US qt 108 X 137 kPa 1 08 X 1 37 kg cm2 1 0 X 1 3 bar 15 6 X 19 9 psi 380 mm 14 96 in 258 mm 10 2 in 24 mm 0 94 in 0 25 L 0 22 Imp qt 0 26 US qt Single suction centrifugal pump 65 43 25 32 1 181 SSS SSS SSS SSS SSS SSS SSS SSS 0 15...

Page 10: ...mshaft lobe dimensions Measurement A Measurement B Max camshaft runout Chain drive right 22 500 X 22 521 mm 0 8858 X 0 8867 in 22 459 X 22 472 mm 0 8842 X 0 8847 in 0 028 X 0 062 mm 0 0011 X 0 0024 in 32 85 X 32 95 mm 1 293 X 1 297 in 25 14 X 25 24 mm 0 990 X 0 994 in 30 75 X 30 85 mm 1 211 X 1 215 in 23 09 X 23 19 mm 0 909 X 0 913 in SSS SSS SSS SSS 32 75 mm 1 289 in 25 04 mm 0 986 in 30 65 mm 1 ...

Page 11: ...stem runout Valve seat width Intake Exhaust 23 4 X 23 6 mm 0 9213 X 0 9291 in 24 9 X 25 1 mm 0 9803 X 0 9882 in 1 76 X 2 90 mm 0 0693 X 0 1142 in 1 76 X 2 90 mm 0 0693 X 0 1142 in 0 9 X 1 1 mm 0 0354 X 0 0433 in 0 9 X 1 1 mm 0 0354 X 0 0433 in 0 5 X 0 9 mm 0 0197 X 0 0354 in 0 5 X 0 9 mm 0 0197 X 0 0354 in 3 975 X 3 990 mm 0 1565 X 0 1571 in 4 460 X 4 475 mm 0 1756 X 0 1762 in 4 000 X 4 012 mm 0 1...

Page 12: ...32 7 mm 1 29 in 32 8 mm 1 29 in 145 9 X 167 9 N 14 88 X 17 12 kg 32 80 X 37 74 lb 164 1 X 188 9 N 16 73 X 19 26 kg 36 89 X 42 46 lb SSS SSS Clockwise Clockwise 37 3 mm 1 47 in 37 3 mm 1 47 in SSS SSS SSS SSS 2 5_ 1 7 mm 0 07 in 2 5_ 1 7 mm 0 07 in SSS SSS Cylinders Cylinder arrangement Bore stroke Compression ratio Bore Max out of round Forward inclined parallel 4 cylinder 77 0 mm 53 6 mm 3 03 2 1...

Page 13: ... X 0 0014 in 76 975 X 76 990 mm 3 0305 X 3 0311 in 5 mm 0 20 in 17 002 X 17 013 mm 0 6694 X 0 6698 in 0 5 mm 0 0197 in Intake side 16 991 X 17 000 mm 0 6689 X 0 6693 in 0 002 X 0 022 mm 0 0001 X 0 0009 in Barrel 0 90 2 75 mm 0 04 0 11 in 0 15 X 0 25 mm 0 0059 X 0 0098 in 0 030 X 0 065 mm 0 0012 X 0 0026 in Taper 0 80 2 75 mm 0 03 0 11 in 0 30 X 0 45 mm 0 0118 X 0 0177 in 0 020 X 0 055 mm 0 0008 X ...

Page 14: ...0 09 mm 0 0035 in SSS Crankshaft Width A Width B Max runout C Big end side clearance D Crankshaft journal to crankshaft journal bearing clearance Bearing color code 55 20 X 56 60 mm 2 17 X 2 23 in 298 8 X 300 7 mm 11 76 X 11 84 in SSS 0 160 X 0 262 mm 0 0063 X 0 0103 in 0 014 X 0 037 mm 0 0006 X 0 0015 in 0 White 1 Blue 2 Black 3 Brown 4 Green SSS SSS 0 03 mm 0 0012 in SSS 0 10 mm 0 0039 in SSS 9 ...

Page 15: ...ity Clutch plates Thickness Plate quantity Max warpage Clutch springs Free length Spring quantity Wet multiple disc Outer pull rack and pinion pull Cable operation Left hand operation 10 X 15 mm 0 39 X 0 59 in Purple 2 9 X 3 1 mm 0 114 X 0 122 in 7 Green 2 9 X 3 1 mm 0 114 X 0 112 in 1 2 9 X 3 1 mm 0 114 X 0 112 in 1 1 9 X 2 1 mm 0 07 X 0 08 in 8 SSS 52 5 mm 2 07 in 6 SSS SSS SSS SSS SSS SSS 2 8 m...

Page 16: ...n 0 08 mm 0 0032 in Shifting mechanism Shift mechanism type Max shift fork guide bar bending Shift drum Guide bar SSS SSS 0 10 mm 0 0039 in Air filter type Oil coated paper element SSS Fuel pump Pump type Model manufacturer Output pressure Electrical 5PW DENSO 294 kPa 2 94 kg cm2 2 94 bar 42 6 psi SSS SSS SSS Throttle position sensor Resistance Output voltage at idle 4 9 X 5 1 kΩ at 20_C 68_F 0 63...

Page 17: ...0 04 in 0 5 mm 0 02 in Front tire Tire type Size Model manufacturer Tire pressure cold 0 X 90 kg 0 X 198 lb 90 X 202 kg 198 X 445 lb High speed riding Min tire tread depth Tubeless 120 70 ZR17 M C 58W Pilot POWER C MICHELIN D218FL DUNLOP 250 kPa 2 5 kgf cm2 2 5 bar 35 6 psi 250 kPa 2 5 kgf cm2 2 5 bar 35 6 psi 250 kPa 2 5 kgf cm2 2 5 bar 35 6 psi SSS SSS SSS SSS SSS SSS SSS 1 6 mm 0 06 in Rear tir...

Page 18: ... mm 0 55 in 30 1 mm and 27 mm 1 19 in and 1 06 in SSS SSS SSS SSS SSS 4 0 mm 0 16 in 0 1 mm 0 004 in 0 5 mm 0 02 in 0 5 mm 0 02 in SSS SSS Rear brake Brake type Operation Recommended fluid Brake pedal freeplay Brake discs Diameter thickness Min thickness Max deflection Brake pad lining thickness inner Brake pad lining thickness outer Master cylinder inside diameter Caliper cylinder inside diameter...

Page 19: ... spring Spring preload adjusting positions Minimum Standard Maximum Rebound damping adjusting positions Minimum Standard Maximum Compression damping adjusting positions Minimum Standard Maximum from the fully turned in position Telescopic fork Coil spring oil damper 120 mm 4 72 in 236 5 mm 9 31 in 100 mm 3 937 in 222 5 mm 8 76 in 8 83 N mm 0 90 kg mm 50 42 lb in 0 X 120 mm 0 X 4 7244 in 43 mm 1 69...

Page 20: ...ng positions Minimum Standard Maximum Compression damping adjusting positions Minimum Standard Maximum from the fully turned in position Swingarm link suspension Coil spring gas oil damper 65 mm 2 56 in 173 5 mm 6 83 in 163 5 mm 6 44 in 83 4 N mm 8 50 kg mm 476 21 lb in 0 X 65 mm 0 00 X 2 56 in No 1 200 kPa 12 kg cm2 12 bar 171 psi 1 4 9 20 17 1 20 12 1 SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS ...

Page 21: ...system System type Model manufacturer Normal output Stator coil resistance color A C magneto F4T850 MITSUBISHI 14 V 560 W at 5 000 r min 0 14 X 0 18 Ω at 20_C 68_F W W SSS SSS SSS SSS Rectifier regulator Regulator type Model manufacture Semi conductor short circuit FH011AA SHINDENGEN SSS SSS No load regulated voltage Rectifier capacity Withstand voltage 14 3 X 15 1 V 50 A 100 V SSS SSS SSS Battery...

Page 22: ...onstant mesh 5VY YAMAHA 0 9 kW 10 8 mm 0 43 in 5 28 X 7 92 N 538 X 808 g 18 99 X 28 48 oz 0 0090 X 0 0110 Ω at 20_C 68_F 24 5 mm 0 96 in 1 5 mm 0 06 in SSS SSS SSS 3 6 mm 0 14 in SSS SSS 23 5 mm 0 93 in SSS Starter relay Model manufacturer Amperage Coil resistance 2768079 A JIDECO 180 A 4 18 X 4 62 Ω at 20_C 68_F SSS SSS SSS Horn Horn type Model manufacturer quantity Max amperage Performance Coil ...

Page 23: ... fuse Fuel injection system fuse Headlight fuse Signaling system fuse Ignition fuse Radiator fan motor fuse Backup fuse odometer and clock Turn signal light fuse Reserve fuse 50 A 1 15 A 1 25 A 1 10 A 1 15 A 1 15 A 2 10 A 1 10 A 1 25 A 15 A 10 A 1 SSS SSS SSS SSS SSS SSS SSS SSS SSS 18 ...

Page 24: ... mm 12 mm 14 mm 16 mm Nm mSkg 6 15 30 55 85 130 0 6 1 5 3 0 5 5 8 5 13 0 ftSlb 4 3 11 22 40 61 94 CONVERSION TABLE GENERAL TIGHTENING TORQUE SPECIFICATIONS SPEC EAS00028 CONVERSION TABLE All specification data in this manual are listed in SI and METRIC UNITS Use this table to convert METRIC unit data to IMPERIAL unit data Ex METRIC MULTIPLIER IMPERIAL mm 0 03937 in 2 mm 0 03937 0 08 in CONVERSION ...

Page 25: ...ater pump assembly sprocket Bolt M6 1 15 1 5 11 Water pump Bolt M6 2 12 1 2 8 7 Thermostat cover Nut M6 2 10 1 0 7 2 Thermostat inlet pipe Bolt M6 1 10 1 0 7 2 Oil cooler Bolt M20 1 63 6 3 46 Engine oil drain bolt Bolt M14 1 43 4 3 31 Oil pipe Bolt M6 2 10 1 0 7 2 Oil strainer Bolt M6 3 10 1 0 7 2 Oil delivery pipe Bolt M6 3 10 1 0 7 2 Oil filter union bolt Bolt M20 1 70 7 0 51 Oil filter M20 1 17...

Page 26: ...er and rear frame Bolt M8 2 23 2 3 17 Muffler cover Bolt M6 2 10 1 0 7 2 Crankcase Stud bolt M10 10 8 0 8 5 8 Crankcase main journal Bolt M9 10 See NOTE 2 Crankcase Bolt M6 10 12 1 2 8 7 Crankcase Bolt M8 1 24 2 4 17 Crankcase Bolt M8 5 24 2 4 17 Generator rotor cover Bolt M6 4 12 1 2 8 7 Generator rotor cover Bolt M8 3 22 2 2 16 Drive sprocket cover Bolt M6 2 10 1 0 7 2 Drive sprocket cover Bolt ...

Page 27: ...2 0 2 1 5 Coolant temperature sensor M12 1 18 1 8 13 Cylinder identification sensor Bolt M6 1 8 0 8 5 7 Atmospheric pressure sensor Screw M5 2 7 0 7 5 0 Crankshaft position sensor Bolt M6 1 10 1 0 7 2 Oil level switch Bolt M6 2 10 1 0 7 2 1 First tighten the bolts to approximately 19 Nm 1 9 mSkg 14 ftSlb with a torque wrench following the tightening order 2 Retighten the bolts 67 Nm 6 7 mSkg 48 ft...

Page 28: ...2 22 TIGHTENING TORQUES SPEC Cylinder head tightening sequence Crankcase tightening sequence 23 ...

Page 29: ...ant reservoir tank and frame M6 5 0 5 3 6 Engine mount front left and right M10 45 4 5 33 Engine mount rear upper M10 51 5 1 37 Engine mount rear under M10 51 5 1 37 Engine mount rear adjust bolt M16 7 0 7 5 1 Catalyst pipe stay and frame M10 44 4 4 32 Clutch cable lock nut engine side M8 7 0 7 5 1 Main frame and rear frame M10 41 4 1 30 Throttle cable adjust nut throttle body side M6 5 0 5 3 6 Co...

Page 30: ... 52 Nm 5 2 mSkg 38 ftSlb with a torque wrench then loosen the ring nut completely 2 Retighten the lower ring nut to specification Refer to INSTALLING THE ENGINE in chapter 5 1 Insert the front wheel axle from the right side and tighten it with the flange bolt from the left side to 91 Nm 9 1 mSkg 65 8 ftSlb 2 In the order from the pinch bolt 2 pinch bolt 1 pinch bolt 2 tighten each bolt to 20 Nm 2 ...

Page 31: ...ump housing Oil strainer Clutch pull rod Oil water pump drive sprocket and washer Clutch thrust plate Starter clutch idle gear inner surface Starter clutch assembly Primary driven gear Transmission gears wheel and pinion Main axle and drive axle Shift drum Shift forks and shift fork guide bars Shift shaft Shift shaft boss Cylinder head cover mating surface Yamaha bond No 1215 Crankcase mating surf...

Page 32: ...upper and lower Relay arm connecting rod and rear shock absorber collar Pivot shaft Swingarm pivot bearing Swingarm head pipe end oil seal and bush Oil seal relay arm connecting arm and rear shock absorber Seat lock assembly moving parts Sidestand pivoting pint and metal to metal moving parts Link and sidestand switch contact point Sidestand hook and spring Shift shaft joint Front wheel oil seal r...

Page 33: ...her location of the right and left relays is acceptable B The lead should not stretch too much C Make sure to insert the coupler and boot to the stay 1 hole D The speedometer lead should not be strained E To the stay 1 hole F Connect after passing over the upper side of the duct 1 Ground lead 2 Meter lead 3 Stay 1 4 Auxiliary light lead right 5 Headlight lead 6 Auxiliary light lead left 7 Console ...

Page 34: ... 1 at the positioning white tape section There should be no slack when clamping Point the tip of the clamp excessive part to the front side of the vehicle Fasten the head light lead with a clamp M Feed a lead wire through the U shape cutout of the console pan el 29 ...

Page 35: ... get along the front side of the main switch after passing it through the guide B Pass the main switch lead through the guide wire C Pass the left handlebar switch lead through the guide wire D Point the tip of the band exces sive part to the rear side of the vehicle and cut the surplus sec tion Clamp it to the outer tube E Clamp the section between 0 and 20 mm 0 and 0 79 in from the split of the ...

Page 36: ...f the clamp and guide wire to the front fork outer tube Cut the tip of the clamp leaving 2 to 4 mm 0 08 X 0 16 in Point the binding part to the external part of the vehicle Clamp it to the outer tube I Cut the tip leaving 2 to 4mm 0 08 X 0 16 in 31 ...

Page 37: ... the tip of the clamp exces sive part to the front side of the vehicle Fasten the right handle bar switch lead with a clamp B To the wire harness C The clutch cable positioning guide should be above the upper end of the clamp Fasten the clutch cable with a clamp Refer to D Position relation between the clamp and guide M CABLE ROUTING SPEC 1 Wire harness 2 Crankshaft position sensor lead 3 Heat pro...

Page 38: ...ead under the swingarm bracket Route the coolant reservoir tank drain hose over the up side of the vehicle L Pass the rear brake light switch lead between the swingarm bracket and coolant reservoir tank M Release the tip of the clamp and install it to the clutch cable Insert the clamp to the hole lo cated on the right back side of the radiator Radiator fan motor lead should not be caught while ins...

Page 39: ...e washer position after routing them between the frame and radiator stay Align the clamp position with the taping sections of leads Point the tip of the clamp surplus section to the down front side of the vehicle What the clamp fastens at this stage are the handlebar switch main switch and immobilizer leads B Pass the main switch lead left handlebar switch lead and im mobilizer lead between the fr...

Page 40: ...th a clamp K Route the water hose so that it is placed at the outermost position finally after routing other leads and hoses in the guide L To the coolant reservoir tank CABLE ROUTING SPEC M There should be no exposure of bared conductors due to the dis placement of the tube N Route the coolant reservoir tank drain hose so that it is routed at the innermost position to each hose and lead O Can be ...

Page 41: ... lead 21 Sidestand switch lead 22 Throttle body lead 23 Coolant reservoir tank drain hose 24 Fuel tank drain hose 25 Cover 7 26 Radiator fan motor lead left 27 Radiator fan motor lead right 28 Wire harness 29 Pipe 3 30 Frame 31 Coolant reservoir tank hose 32 Thermo stat assembly breather hose CABLE ROUTING SPEC 1 Heat protector 2 Crankshaft position sensor lead 3 Neutral switch lead 4 Ground lead ...

Page 42: ...n three protrusions of the pipe the first and second parts from the ve hicle front Point the tip of the clamp excessive part to the in side of the vehicle D To the vehicle right side diagram E To the engine F Clamp the lead between three protrusions of the pipe the in side and outside of the vehicle G Point the tip of the clamp exces sive part to the inside of the ve hicle H All hoses and leads sh...

Page 43: ...s on the tip of the clamp af ter passing the leads through it R Insert the tail brake light lead to the rear frame hole S Insert the clamp from the vehicle front to the rear side and fasten each lead coupler and onion head to the fender rib and then point the tip of the clamp exces sive part to the upper side of the vehicle T Hold down the clamp tips after passing each lead U Make sure to position...

Page 44: ...y negative lead A C magneto lead and starter motor lead with a clamp AA To the speed sensor BB Insert the wire harness wrap ping clamp to the hole of the frame CC After passing the lead be tween the wire harness and starter motor leads fastening by the clamp should be can celled and route the lead un der the idle remote controller CABLE ROUTING SPEC HH Insert the wire harness wrap ping clamp to th...

Page 45: ...n be inserted in any direction NN Route each lead higher than the frame plate pass it to the inside of the vehicle from the hole Leads should be routed in random order Clamp can be inserted in any direction OO The hoses should not be lo cated higher than the throttle body side cap over the up side of the vehicle CABLE ROUTING SPEC 40 ...

Page 46: ...ctions are per fectly equipped A B C A Install the lip of O ring facing up ward B Install the part pointing the white paint part of the hose to the left side of the vehicle C Any direction of the clip grip can be accepted D Install the clip grip as specified in the drawing E Install the part pointing the white paint part of the hose to the left side of the vehicle F Point the clip grip to the left...

Page 47: ...heck valve clearance S Adjust Every 40 000 km 4 Air filter element See page 3 32 S Replace Ǹ 5 Clutch See page 3 31 S Check operation Ǹ Ǹ Ǹ Ǹ Ǹ 6 Front brake S Check operation fluid level and vehicle for fluid leakage Ǹ Ǹ Ǹ Ǹ Ǹ Ǹ 6 See page 3 42 44 45 S Replace brake pads Whenever worn to the limit 7 Rear brake S Check operation fluid level and vehicle for fluid leakage Ǹ Ǹ Ǹ Ǹ Ǹ Ǹ 7 See page 3 43...

Page 48: ...tion Ǹ Ǹ Ǹ Ǹ Ǹ Ǹ 26 Moving parts and cables See page 3 61 S Lubricate Ǹ Ǹ Ǹ Ǹ Ǹ 27 Throttle grip housing and cable See page 3 22 S Check operation and free play S Adjust the throttle cable free play if necessary S Lubricate the throttle grip housing and cable Ǹ Ǹ Ǹ Ǹ Ǹ 28 Air induction system See page 7 46 S Check the air cut off valve reed valve and hose for dam age S Replace any damaged parts if...

Page 49: ...Y L Yellow Blue Y R Yellow Red Y W Yellow White YZF R1 S 2004 WIRING DIAGRAM Main switch A C magneto Rectifier regulator Fuse main Fuse backup Immobilizer unit Battery Fuse fuel injection Starter relay Starter motor Starting circuit cut off relay Neutral switch Sidestand switch Fuel pump ECU Ignition coil 1 Ignition coil 2 Ignition coil 3 Ignition coil 4 Spark plug Injector 1 Injector 2 Injector 3...

Page 50: ...YZF R1 S 2004 WIRING DIAGRAM ...

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