Yamaha YZF-R1 2004 Service Information
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Yamaha YZF-R1 2004 Service Information

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2004
YZF-R1(S)
5VY1-SE1
SERVICE
INFORMATION
Yamaha Motor Co., Ltd.

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  • Page 1 2004 YZF-R1(S) 5VY1-SE1 SERVICE INFORMATION Yamaha Motor Co., Ltd.
  • Page 2 This service information 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 Yamaha Motor Co., Ltd.
  • Page 3 EAS00002 NOTICE This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manu- al. 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.
  • Page 4 EAS00008 SYMBOLS The following symbols are not relevant to every SPEC vehicle. INFO Symbols 1 to 9 indicate the subject of each chapter. 1 General information 2 Specifications CHAS 3 Periodic checks and adjustments 4 Chassis 5 Engine 6 Cooling system COOL 7 Fuel injection system 8 Electrical system...
  • Page 5 CONTENTS GENERAL INFORMATION MOTORCYCLE IDENTIFICATION ....... 1 VEHICLE IDENTIFICATION NUMBER ......1 MODEL LABEL .
  • Page 6 MOTORCYCLE IDENTIFICATION INFO EAS00014 GENERAL INFORMATION MOTORCYCLE 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.
  • Page 7 SPEC GENERAL SPECIFICATIONS SPECIFICATIONS GENERAL SPECIFICATIONS Item Standard Limit Model code 5VY1 (EUR), 5VY2 (FRA), 5VY3 (AUS) Dimensions Overall length 2,065 mm (8.13 in) Overall width 720 mm (28.3 in) Overall height 1,105 mm (43.5 in) Seat height 835 mm (32.9 in) Wheelbase 1,395 mm (54.9 in) Minimum ground clearance...
  • Page 8 SPEC ENGINE SPECIFICATIONS ENGINE SPECIFICATIONS Item Standard Limit Engine Engine type Liquid-cooled, 4-stroke, DOHC Displacement 998 cm (60.90 cu.in) Cylinder arrangement Forward-inclined parallel 4-cylinder Bore stroke 77.0 53.6 mm (3.03 2.11 in) Compression ratio 12.4 : 1 1,150 X 1,250 r/min Engine idling speed Vacuum pressure at engine idling 22 kPa (165 mmHg, 6.5 inHg)
  • Page 9 SPEC ENGINE SPECIFICATIONS Item Standard Limit Oil filter Oil filter type Paper 80 X 120 kPa (0.8 X 1.2 kg/cm Bypass valve opening pressure 0.8 X 1.2 bar, 11.6 X 17.4 psi) Oil pump Oil pump type Trochoid 0.01 X 0.10 mm Inner-rotor-to-outer-rotor-tip 0.18 mm (0.0004 X 0.0039 in)
  • Page 10 SPEC ENGINE SPECIFICATIONS Item Standard Limit Camshafts Drive system Chain drive (right) 22.500 X 22.521 mm (0.8858 X 0.8867 in) Camshaft cap inside diameter 22.459 X 22.472 mm (0.8842 X 0.8847 in) Camshaft journal diameter 0.028 X 0.062 mm (0.0011 X 0.0024 in) Camshaft-journal-to-camshaft- cap clearance Intake camshaft lobe dimensions...
  • Page 11 SPEC ENGINE SPECIFICATIONS Item Standard Limit Timing chain Model/number of links RH2020 /122 Tensioning system Automatic Valves, valve seats, valve guides Valve clearance (cold) 0.11 X 0.20 mm (0.0043 X 0.0079 in) Intake 0.21 X 0.25 mm (0.0083 X 0.0098 in) Exhaust Valve dimensions Head Diameter...
  • Page 12 SPEC ENGINE SPECIFICATIONS Item Standard Limit Valve springs Free length Intake 39.3 mm (1.55 in) 37.3 mm (1.47 in) Exhaust 39.3 mm (1.55 in) 37.3 mm (1.47 in) Installed length (valve closed) Intake 32.7 mm (1.29 in) Exhaust 32.8 mm (1.29 in) Compressed spring force (installed) 145.9 X 167.9 N (14.88 X 17.12 kg,...
  • Page 13 SPEC ENGINE SPECIFICATIONS Item Standard Limit Piston 0.010 X 0.035 mm (0.0004 X 0.0014 in) Piston-to-cylinder clearance 0.120 mm (0.0047 in) 76.975 X 76.990 mm (3.0305 X 3.0311 in) Diameter D Height H 5 mm (0.20 in) Piston pin bore (in the piston) 17.002 X 17.013 mm Diameter 17.043 mm...
  • Page 14 SPEC ENGINE SPECIFICATIONS Item Standard Limit Connecting rods 0.034 X 0.058 mm (0.0013 X 0.0023 in) Crankshaft-pin-to-big-end-bearing 0.09 mm clearance (0.0035 in) Bearing color code 1 = Blue 2 = Black 3 = Brown 4 = Green Crankshaft 55.20 X 56.60 mm (2.17 X 2.23 in) Width A 298.8 X 300.7 mm (11.76 X 11.84 in) Width B...
  • Page 15 SPEC ENGINE SPECIFICATIONS Item Standard Limit Clutch Clutch type Wet, multiple disc Clutch release method Outer pull, rack and pinion pull Clutch release method operation Cable operation Operation Left-hand operation 10 X 15 mm (0.39 X 0.59 in) Clutch cable free play (at the end of the clutch lever) Friction plates Color code...
  • Page 16 SPEC ENGINE SPECIFICATIONS Item Standard Limit Transmission Transmission type Constant mesh, 6-speed Primary reduction system Spur gear Primary reduction ratio 65/43 (1.512) Secondary reduction system Chain drive Secondary reduction ratio 45/17 (2.647) Operation Left-foot operation Gear ratios 1st gear 38/15 (2.533) 2nd gear 33/16 (2.063) 3rd gear...
  • Page 17 SPEC CHASSIS SPECIFICATIONS CHASSIS SPECIFICATIONS Item Standard Limit Frame Frame type Diamond Caster angle Trail 97 mm (3.82 in) Front wheel Wheel type Cast wheel Size 17 M/C MT3.50 Material Aluminum Wheel travel 120 mm (4.72 in) Wheel runout Max. radial wheel runout 1 mm (0.04 in) Max.
  • Page 18 SPEC CHASSIS SPECIFICATIONS Item Standard Limit Front brakes Brake type Dual disc brake Operation Right hand operation Recommended fluid DOT 4 2.3 X 11.5 mm (0.09 X 0.45 in) Brake lever free play Brake discs Diameter thickness 4.5 mm (12.60 0.18 in) Min.
  • Page 19 SPEC CHASSIS SPECIFICATIONS Item Standard Limit Front suspension Suspension type Telescopic fork Front fork type Coil spring/oil damper Front fork travel 120 mm (4.72 in) Spring Free length 236.5 mm (9.31 in) 231.8 mm (9.13 in) Spacer length 100 mm (3.937 in) Installed length 222.5 mm (8.76 in) Spring rate (K1)
  • Page 20 SPEC CHASSIS SPECIFICATIONS Item Standard Limit Steering Steering bearing type Angular bearing Lock to lock angle (left) Lock to lock angle (right) Rear suspension Suspension type Swingarm (link suspension) Rear shock absorber assembly Coil spring/gas-oil damper type Rear shock absorber assembly 65 mm (2.56 in) travel Spring...
  • Page 21 SPEC ELECTRICAL SPECIFICATIONS ELECTRICAL SPECIFICATIONS Item Standard Limit System voltage 12 V Ignition system Ignition system type DC. T.C.I. Ignition timing 5_ BTDC at 1,050 r/min 336 X 504 Ω at 20_C (68_F)/Gy-B Crankshaft position sensor resistance/color T.C.I. unit model (manufacturer) F8T820 (MITSUBISHI) (EUR, AUS) F8T821 (MITSUBISHI) (FRA) Ignition coils...
  • Page 22 Engine trouble warning light Shift timing indicator light Immobilizer indicator light Electric starting system System type Constant mesh Starter motor Model (manufacturer) 5VY (YAMAHA) Power output 0.9 kW Brushes Overall length 10.8 mm (0.43 in) 3.6 mm (0.14 in) 5.28 X 7.92 N (538 X 808 g, Spring force 18.99 X 28.48 oz)
  • Page 23 SPEC ELECTRICAL SPECIFICATIONS Item Standard Limit Fuses (amperage quantity) Main fuse 50 A Fuel injection system fuse 15 A Headlight fuse 25 A Signaling system fuse 10 A Ignition fuse 15 A Radiator fan motor fuse 15 A Backup fuse (odometer and clock) 10 A Turn signal light fuse 10 A...
  • Page 24 CONVERSION TABLE/ SPEC GENERAL TIGHTENING TORQUE SPECIFICATIONS EAS00028 EAS00030 CONVERSION TABLE GENERAL TIGHTENING TORQUE All specification data in this manual are listed in SPECIFICATIONS SI and METRIC UNITS. This chart specifies tightening torques for stan- Use this table to convert METRIC unit data to dard fasteners with a standard ISO thread IMPERIAL unit data.
  • Page 25 SPEC TIGHTENING TORQUES TIGHTENING TORQUES ENGINE TIGHTENING TORQUES Tightening torque Thread Item Item Fastener Fastener Q’ty Q ty Remarks Remarks size mSkg ftSlb Spark plugs — Cylinder head See NOTE 1 Bolt Camshaft caps Bolt Cylinder head cover Bolt Cylinder head (exhaust pipe) Stud bolt Air indication system cap Bolt...
  • Page 26 SPEC TIGHTENING TORQUES Tightening torque Thread Item Item Fastener Fastener Q’ty Q ty Remarks Remarks size mSkg ftSlb Exhaust pipe and cylinder head Catalyst pipe assembly and Bolt muffler Exhaust pipe and exhaust valve Bolt pipe assembly Exhaust valve pipe and housing Bolt Pulley and shaft arm EXUP pulley bracket...
  • Page 27 SPEC TIGHTENING TORQUES Tightening torque Thread Item Item Fastener Fastener Q’ty Q ty Remarks Remarks size mSkg ftSlb Main axle bearing housing Bolt Shift fork shaft stopper Bolt Stopper screw Screw Shift rod lock nut (rear) Left thread Shift rod lock nut (front) Shift rod joint Bolt Shift arm...
  • Page 28 SPEC TIGHTENING TORQUES Cylinder head tightening sequence: Crankcase tightening sequence. 2-22...
  • Page 29 SPEC TIGHTENING TORQUES CHASSIS TIGHTENING TORQUES Tightening Thread Item Item Remarks Remarks size mSkg ftSlb Upper bracket and outer tube Upper bracket and steering stem nut 11.3 Handlebar and outer tube Handlebar and upper bracket Steering shaft and ring nut See NOTE 1 Outer tube and under bracket Main switch and upper bracket...
  • Page 30 SPEC TIGHTENING TORQUES Tightening Thread Item Item Remarks Remarks size mSkg ftSlb Battery box and frame Atmospheric pressure sensor and battery box — 0.07 Lean angle cut-off switch and battery box — Foot rest bracket (front) and frame Foot rest bracket (rear) and frame Rear brake master cylinder and foot rest bracket Rear brake hose union bolt Sidestand bracket and frame...
  • Page 31 Transmission gears (wheel and pinion) Main axle and drive axle Shift drum Shift forks and shift fork guide bars Shift shaft Shift shaft boss Yamaha bond Cylinder head cover mating surface No.1215 Yamaha bond Crankcase mating surface No.1215 Yamaha bond Clutch cover (crankcase mating surface) No.1215...
  • Page 32 SPEC LUBRICATION POINTS AND LUBRICANT TYPES EAS00032 CHASSIS Lubrication point Lubricant Steering bearings and bearing races (upper and lower) Throttle grip inner surface Brake lever pivoting point and metal-to-metal moving parts Clutch lever pivoting point and metal-to-metal moving parts Engine mount bolts (rear upper and lower) Relay arm, connecting rod and rear shock absorber collar Pivot shaft Swingarm pivot bearing...
  • Page 33 SPEC CABLE ROUTING EAS00035 CABLE ROUTING Ground lead A Insert to the rib of the head light. G Clamp the head light lead by Meter lead (Either location of the right and wrapping and insert it to the in- Stay 1 left relays is acceptable.) take air grill hole.
  • Page 34 SPEC CABLE ROUTING L Clamp the head light lead to the stay 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.
  • Page 35 SPEC CABLE ROUTING Right handlebar switch lead A Route the clutch cable so as to F Clamp the leads inside the front Clutch cable get along the front side of the fork of the vehicle. Point the exit Main switch lead main switch after passing it of the horn lead to the left front Left handlebar switch lead...
  • Page 36 SPEC CABLE ROUTING H Clamp the assembly of 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.
  • Page 37 SPEC CABLE ROUTING Wire harness A Clamp it after passing between E Clamp the clamp upper end Crankshaft position sensor lead the frame and radiator stay. along the line of lower end of the Heat protector Point the tip of the clamp (exces- hose clamp assembly.
  • Page 38 SPEC CABLE ROUTING I The coupler for the air induction L Pass the rear brake light switch solenoid lead and camshaft sen- lead between the swingarm sor lead should be connected bracket and coolant reservoir above the ignition coil sub wire tank.
  • Page 39 SPEC CABLE ROUTING Heat protector A Clamp the leads so that they are C Fold back the clamp and secure Main switch lead positioned inner of the vehicle it after passing the lead through Left handlebar switch lead than the washer position after the clamp.
  • Page 40 SPEC CABLE ROUTING G Route the lead by the inside of M There should be no exposure of R Arrange so as not for each hose the water hose and water pipe. bared conductors due to the dis- to cross in the part between “BB” H Route the lead by the inside of placement of the tube.
  • Page 41 SPEC CABLE ROUTING Heat protector Battery negative lead Throttle body side cap Crankshaft position sensor lead Starter motor lead Mud guard Neutral switch lead A.C.magneto lead Turn signal light lead Ground lead Oil level switch lead License plate light lead Coolant reservoir tank Sidestand switch lead Rear fender rib...
  • Page 42 SPEC CABLE ROUTING A Pass the wire harness through G Point the tip of the clamp (exces- K Pass the water hose lower side the clamp inserted to the radiator sive part) to the inside of the ve- of the thermostat, and between stay.
  • Page 43 SPEC CABLE ROUTING P Pass the lead through inside of U Make sure to position the cou- W Point the tip of the clamp (sur- the battery band. pler at the downmost position of plus section) to the rear side of Q Press on the tip of the clamp af- leads.
  • Page 44 SPEC CABLE ROUTING Z Point the tip of the clamp (exces- DD Fasten the wire harness, HH Insert the wire harness wrap- sive part) to the down side of the A.C.magneto lead, ping clamp to the hole of the vehicle. Fasten the wire har- throttle body lead with a frame.
  • Page 45 SPEC CABLE ROUTING MM Route each lead lower than PP Route the leads in random or- the frame plate. Leads should der. be routed in random order. Clamp can 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.
  • Page 46 SPEC CABLE ROUTING Fuel tank A Install the lip of O-ring facing up- a Fuel piping connector attach- O-ring ward. ment directions. (fuel pump side) Fuel tank drain hose B Install the part pointing the white 1. Insert the connector until the Fuel tank breather hose paint part of the hose to the left click sound is heard and check...
  • Page 47 S The annual checks must be performed every year, except if a kilometer-based maintenance is per- formed instead. S From 50,000 km, repeat the maintenance intervals starting from 10,000 km. S Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills. ODOMETER READING...
  • Page 48 PERIODIC MAINTENANCE AND LUBRICATION INTERVALS ODOMETER READING ANNUAL 1,000 km) ITEM CHECK OR MAINTENANCE JOB CHECK CHECK S Check operation. Sidestand S Lubricate. (See page 3-61) Sidestand switch S Check operation. (See page 3-61, 8-4) Front fork S Check operation and for oil leakage. (See page 3-53) Shock absorber S Check operation and shock absorber for oil leakage.
  • Page 49 YZF-R1(S) 2004 WIRING DIAGRAM Main switch Clutch switch A.C. magneto Turn signal switch Rectifier/ regulator Horn Fuse (main) Front turn signal light (left) Fuse (backup) Front turn signal light (right) Immobilizer unit Rear turn signal light (left) Battery Rear turn signal light (right) Fuse (fuel injection) Headlight Starter relay...
  • Page 50 YZF-R1(S) 2004 WIRING DIAGRAM...

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