YEC ’04 YZF-R1 Kit Manual
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YEC ’04 YZF-R1 Kit Manual

The performance edge for top-ranking riders
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'04 YZF-R1
KIT MANUAL
The Performance Edge
for top-ranking riders

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Summary of Contents for YEC ’04 YZF-R1

  • Page 1 ’04 YZF-R1 KIT MANUAL The Performance Edge for top-ranking riders...
  • Page 2 2004 YZF-R1 Kit Manual Please note : • It should be understood that these kit parts are not covered by warranty. • The manufacturer does not assume any responsibility for problems caused by these parts. • These kit parts are intended for racing alone. They are not to be used in any circumstances on public roads.

  • Page 3: Table Of Contents

    CONTENTS Standard Specifications ...................1 Kit Parts ......................2 2-1 Basic Kit Set Contents................2 2-2 Engine Parts ....................2 Maintenance set (5VY-MAINT-70)............2 Spark Plugs ..................3 AIS Plug Set (5VY-A4890-70) .............3 Gaskets....................4 High-lift Camshaft, Valve Spring ............5 Standard-lift Camshafts ..............6 Flat Valve Set (5VY-A2100-70)............7 Sub-radiator Set (5VY-A240A-70) ............8 Funnel Set (5VY-A4460-70) ...............9 10.
  • Page 4 Installation Precautions ..................40 3-1 Checking the Valve Seats ...............40 3-2 Selecting the crankshaft bearing............42 3-3 Selecting the connecting rod bearing ...........43 3-4 Installing the piston, piston ring and connecting rod ......45 3-5 Crankcase installation ................47 3-6 Cylinder head tightening (calibrated wrench tightening method)..48 3-7 Camshaft installation ................49 3-8 Cam chain tensioner installation ............50 3-9 Engine mounting ..................51...

  • Page 5: Standard Specifications

    1 Standard Specifications Item Standard Basic Kit Displacement 998 cm Bore/stroke 77,0 mm/53,6 mm Primary reduction gear ratio 65/43 (1.512) Compression ratio 12.4:1 13.3:1 Surface honing 0,45 mm Squish height 0,75 mm 0,60 mm Camshaft INT 5VY-00 5VY-70 Nominal 292° – 7.6 286 –...

  • Page 6: Kit Parts

    2 Kit Parts 2-1 Basic Kit Set Contents Spark plug set Head gasket (0.30 mm) High lift camshaft (INT, EXT) Valve spring set Funnel set AIS plug set Clutch spring set ACM rotor Wire harness set Engine control unit Kit manual Note: The part marked [ * ] at the top of the parts list is included in the kit, but if it is specifically needed, it is available from Yamaha authorized dealers.

  • Page 7: Spark Plugs

    Spark Plugs Parts List PART No. PART NAME Q’TY REMARKS 5 FL-94700-70 PLUG, SPARK NGK R0045Q-10 Set No. : 5FL-R045Q-70 (R0045Q-10, 4 plugs) CAUTION : Since these spark plugs have a copper gasket, caution is needed during installation on the following points. 1.

  • Page 8: Gaskets

    REMOVE Gaskets Parts List PART No. PART NAME Q’TY REMARKS 5VY-11181-70 GASKET, HEADCYL. t=0,30 mm 5VY-11181-80 GASKET, HEADCYL. t=0,35 mm 5VY-11351-70 GASKET, CYL. t=0,10 mm 5VY-11351-80 GASKET, CYL. t=0,15 mm These parts are used to adjust the squish height and compression ratio. They should be installed in the direction, which enables the punched alpha-numeral “5VY”...

  • Page 9: High-Lift Camshaft, Valve Spring

    High-lift Camshaft, Valve Spring High-lift specification PART No. PART NAME Q’TY REMARKS 5VY-12171-70 SHAFT, CAM 1 5VY-12181-70 SHAFT, CAM 2 90105-07003 5VY-12176-00 When using these camshafts, the valve springs should also be those in the kit. Specification Nominal Working angle Major Axis 286-8.5 33.8...

  • Page 10: Standard-Lift Camshafts

    To adjust the valve timing, use the oval holes of the standard cam sprocket. USE THESE OVAL HOLES FOR TIMING ADJUSTMENT. Standard-lift Camshafts Parts List PART No. PART NAME Q’TY REMARKS 5VY-12171-80 SHAFT, CAM 1 5VY-12181-80 SHAFT, CAM 2 Specification Nominal Working angle Major axis...

  • Page 11: Flat Valve Set (5Vy-A2100-70)

    Flat Valve Set (5VY-A2100-70) Parts List PART No. PART NAME Q’TY REMARKS 5VY-12111-70 VALVE, INTAKE Centre of intake (L=87.16) 5VY-12112-70 VALVE, INTAKE 2 Side of intake (L=88.34) 5VY-12121-70 VALVE, EXT. These valves are used to improve the compression ratio (about 0.2) by making their shape on the compression chamber side flatter than in the case of standard valves.

  • Page 12: Sub-Radiator Set (5Vy-A240A-70)

    Sub-radiator Set (5VY-A240A-70) Parts List PART No. PART NAME Q’TY REMARKS 5VY-1240A-70 RADIATOR ASS’Y 95817-06012 BOLT 90430-06014 GASKET 90480-15363 GROMMET 90387-0614M COLLAR 95827-06030 BOLT 90201-06071 WASHER 5VY-12637-70 STAY 95807-06016 BOLT 5VY-12467-70 COVER, RADIATOR 90465-13275 CLAMP 5VY-12483-70 PIPE, 3 5VY-12579-70 HOSE, 4 90450-35001 HOSE CLAMP ASS’Y 5VY-1243F-70...

  • Page 13: Funnel Set (5Vy-A4460-70)

    Funnel Set (5VY-A4460-70) Parts List PART No. PART NAME Q’TY REMARKS 5VY-14477-70 PLATE 5VY-14469-70 FUNNEL, 1 L=27 mm 5VY-14469-90 FUNNEL, 1 L=46 mm CAUTION : • The air cleaner case is kept fixed by the standard funnel. Remove this standard funnel and install the plate in its destined place. •...

  • Page 14: Clutch Spring, Clutch Boss

    INSTALL WITH THE MACHINED SIDE DOWN. 10. Clutch Spring, Clutch Boss Parts List PART No. PART NAME Q’TY REMARKS 5VY-16334-70 SPRING, CLUTCH 5VY-16371-70 BOSS, CLUTCH The clutch spring has a 10% better load capacity than the standard one. - 10 -...

  • Page 15: Acm Rotor

    The clutch boss has been surface-treated for improved durability. Use nine (9) 5VY-16321-00 plates as friction plates. 5VY-16351-00 90159-06009 5VY-16325-00 5VY-16321-00 90179-20007 90208-20001 11. ACM Rotor Parts List PART No. PART NAME Q’TY REMARKS 5SL-81450-70 ROTOR DIRECTION OF ONE-WAY CLUTCH ROTATION INSTALL STD PARTS - 11 -...

  • Page 16: Engine Control Unit (Ecu)

    This rotor is narrower than the standard rotor, aiming at a reduced inertia mass and frictional load. For the stator coil, use standard one. CAUTION : • The rotor and starter clutch are integrated. Use a standard starter clutch. • After the installation of the starter clutch, check for direction of rotation. •...
  • Page 17 NOTE on meter display: Connection of the ECU kit allows the standard meter to switch to the kit mode. STD : Clock STD : Water Temp. Kit : Max. Water Temp. Kit : No Display Retains Max. Temp. uring Run STD : ODO/TRIP Etc.
  • Page 18 THE INJECTION VOLUME F5 TO F9 IS ADJUSTED IN THE SAME WAY AS FOR F4. F4 F5 F6 F7 F8 F9 3000 9000 10000 11000 12000 13000 ENGINE SPEED (rpm) RANGE OF ADJUSTMENT OF THE VOLUME OF INJECTION F1 TO F9 F0: Transfer to the adjustment mode is shown in the display area at the bottom RHS of the meter.
  • Page 19 B. Ignition Timing Correction CAUTION : This function corrects the gaps for the optimum ignition timing according to the difference of the characteristics of the fuel used. Ignition timing must not be set at too early a (plus side) timing since it may cause problems.
  • Page 20 Procedure (fuel adjustment, ignition timing correction, and adjustment of RAM-pressure fuel correction volume) Transfer to F0 mode Keeping both the “SELECT” and “RESET” buttons pressed simultaneously, turn on the main switch. “F0 ” appears in the display area at the bottom RHS of the meter. Transfer to the ECU applicable mode Keeping both the SELECT and RESET buttons pressed simultaneously.
  • Page 21 Initialization (Bring all settings to “0”.) Press the “RESET” or “SELECT” button with “FE_YY” displayed. “FE_88” will appear. While checking this display, simultaneously keep both the “RESET” and “SELECT” buttons pressed. “FE_ 0” will be displayed and this completes initialisation. Turn off the main switch to end.
  • Page 22 <Operation Procedure for F1 to FD Fuel Amount/Ignition Timing Adjustment> Item Operation Meter display Significance a Mode Transfer Keep "RESET" + "SELECT" [______] simultaneously pressed and turn on "MAIN SWITCH". b ECU Applicable Value [F0____] "F0" indicates ECU applicable value Adjustment/Diagnostic Adjustment mode.
  • Page 23 <Operation Procedure for Initialization of Adjustment Values> Item Operation Meter display Significance (Items and their operating procedures are the same as <Operating procedure for F1 to FD fuel volume/ignition timing adjustment> i Determine Applicable item After selecting FE in above, keep [FE___*] Number of changes in adjustment (Code FE)
  • Page 24 Self-diagnosis Function Function This function detects a failure in the sensor and the actuator and alerts the user to the occurrence of failure by lighting up a pilot light on meter / displaying a fail- ure code and simultaneously launching the evacuation procedure. Operation Abnormality: The alarm comes on (during engine run), Alarm comes on + Abnormality code appears (engine at standstill)
  • Page 25 Failure Item Major cause of failure Engine code operation Ignition failure • Broken line between ignition coil and ECU Possible of #3 cylinder • Failure in ignition coil interior Ignition failure • Broken line between ignition coil and ECU Possible of #4 cylinder •...
  • Page 26 Diagnosis Function (Status Checking Function) Function To help users with troubleshooting and maintenance, sensor output display and actuator operation are made possible without the use of special tools or measuring instruments. Procedure • Transfer to diagnostic mode as follows: • Hold down "RESET" and "SELECT" buttons on meter and turn on the main switch.

  • Page 27: Wire Harness

    Code selected Item Description Injector #1 Injector #2 • Turning the engine switch off and on activates the injector 5 times. Injector #3 Injector #4 Main relay • Turning the engine switch off and on activates main relay 5 times. •...
  • Page 28 WIRING DIAGRAM - 24 -...

  • Page 29: Chassis Parts

    2-3 Chassis Parts 15. Oil Catcher Tank Set (5VY-C1707-70) Parts List PART No. PART NAME Q’TY REMARKS 5VY-21707-70 CATCH TANK COMP. Capacity: 630 cc 5EB-15373-70 HOSE 90450-25037 HOSE CLAMP ASS'Y 5SL-11166-70 PIPE, BREATHER 1 371-11167-01 PIPE, BREATHER 1 4XV-21376-00 BAND 90464-08002 CLAMP PASS UNDER TANK STAY...

  • Page 30: Chassis Protector Set (5Vy-C117G-70)

    16. Chasis Protector Set (5VY-C117G-70) Parts List PART No. PART NAME Q’TY REMARKS 5VY-2117G-70 PROTECTOR 5SL-21472-70 COLLAR, PROTECTOR LH. 5SL-21477-70 COLLAR, PROTECTOR RH. 91317-10070 BOLT, HEX. SOCKET 90201-105R9 WASHER FRAME FRAME ENGINE RIGHT LEFT Remove the bolt holding the head and using the bolt supplied, install the chassis protector and cut the cowling to fit the vehicle.

  • Page 31: Front Fork Spring Set

    18. Front Fork Spring Set 5VY-1244H-70 PART No. PART NAME Q’TY REMARKS 5VY-23141-70 FR. FORK SPRING 0,95 kgf/mm 5PW-23118-00 SPACER 4XV-23142-00 SEAT, SPRG UPPER 5VY-C3141-80 PART No. PART NAME Q’TY REMARKS 5VY-23141-80 FR. FORK SPRING 1,00 kgf/mm 5PW-23118-00 SPACER 4XV-23142-00 SEAT, SPRG UPPER Specification –70...

  • Page 32: Front Disk Assembly (5Vy-2581T-70)

    5VY-23111-00 3XJ-23147-L0 3XC-23357-00 19. Front Disk Assembly (5VY-2581T-70) Parts List PART No. PART NAME Q’TY REMARKS 5VY-2582T-70 DISK, BRAKE Fr. t=5,0 5VY-25832-70 BRACKET, DISK 5EB-2581M-70 PIN, FLOATING 5EB-2581N-70 WASHER 93430-09052 CIRCLIP 90109-064G6 BOLT This assembly is of the fully floating type, with the outer rotor 5 mm thick for improved durability when racing.

  • Page 33: Front Wheel Attachment Set

    20. Front Wheel Attachment Set This fixing assembly is intended for the TZ250 Marchesini wheel. TZ250 MARCHESINI WHEEL - 29 -...

  • Page 34: Rear Arm Attachment Set, Rear Wheel Attachment Set

    21. Rear Arm Attachment Set, Rear Wheel Attachment Set Rear Arm Attachment Set (5VY-C2170-70) Parts List PART No. PART NAME Q’TY REMARKS 5VY-25388-70 PULLER 1 95317-20700 99009-32500 CIRCLIP 4FN-25322-70 INSERT, SHAFT 90110-06142 BOLT 4XV-25379-70 BOLT, PULLER 5VY-25389-70-0 PULLER 2 4XV-25381-70 AXLE, WHEEL Rr.
  • Page 35 When using this set, it is necessary to reduce the length of the rear arm by 5 mm since contact is made between the rear arm and puller 2. SCRAPE AWAY If a more competitive system is desired, with a rear arm for endurance racing, please contact the following company: MG Competition ZAE LA FORET N°...
  • Page 36 Rear Wheel Attachment Set (4XV-C5310-80) Parts List PART No. PART NAME Q’TY REMARKS 4XV-25767-70 COLLAR, DISK BRAKE 5FL-93307-70 BEARING 4XV-25317-80 SPACER, BEARING 4XV-2582V-80 DISK, BRAKE 91317-08025 BOLT 4XV-25832-80 BRACKET, DISK 90149-06286 SCREW 90185-06122 4XV-25683-80 SPACER 4FN-25366-70 CLUTCH, HUB 4XV-2539F-70 PLATE 91317-10025 BOLT 90185-10037...
  • Page 37 This fixing assembly is intended for Marchesini wheel 72186 (for Yamaha Super Bike). When using a different wheel, refer to the hub size below. (chain line) (disk line) DAMPER Marchesini 4031 - 33 -...

  • Page 38: Sprocket, Sprocket Nut

    22. Sprocket, Sprocket Nut Parts List PART No. PART NAME Q’TY REMARKS 4XV-17460-75 SPROCKET, DRIVE 15T, 520SIZE 4XV-17460-76 SPROCKET, DRIVE 16T, 520SIZE 4XV-17460-77 SPROCKET, DRIVE 17T, 520SIZE 4XV-17463-70 NUT, SPROCKET FOR KIT SPROCKETS 4XV-25441-70 Rr. SPROCKET 41T FOR STD WHEEL 520SIZE 4XV-25442-70 Rr.
  • Page 39 This kit has an operation angle of 57°, resulting in an improved racing operation. The use of the "5SL-26243-71" with the tube guide included in the R6 kit, allows an operating angle of 52°. - 35 -...

  • Page 40: Footrest Set (5Vy-C7400-70)

    24. Footrest Set (5VY-C7400-70) Parts List PART No. PART NAME Q’TY REMARKS 5SL-27412-70 BRKT., 1 5VY-27452-70 BRKT., FOOTREST 1 90151-08022 SCREW 90109-085G6 BOLT 4JT-27411-20 FOOTREST 1 97007-06020 BOLT 92907-06600 WASHER, PLATE 5FL-27445-00 PLATE 1 92017-06012 BOLT, BUTTON HEAD 5PW-18111-71 PEDAL, SHIFT 5EB-18162-70 PEDAL, FRONT 98707-06020...
  • Page 41 Install the rear brake return spring to the master cylinder with the rubber boot removed. This footrest is located on the lower side 5 mm to the rear, at the same height as that of the standard. A change of 10 mm in height and of 5 mm to the rear of this location can be made for each step.

  • Page 42: Front Stay Set (5Vy-C8350-70)

    25. Front Stay Set (5VY-C8350-70) Parts List PART No. PART NAME Q’TY REMARKS 5VY-28356-70 STAY, 1 5VY-83519-70 BRACKET, METER 90149-06298 SCREW 95707-06500 4XV-83513-00 DAMPER 5VY-28321-70 STAY 1 5VY-28322-70 STAY 2 95807-06040 BOLT 5PW-28386-00 HEAD 5PW-2177L-00 PLATE, SPRING 90201-08008 WASHER Use standard parts except for those supplied. USE STD PARTS - 38 -...

  • Page 43: Other

    2-4 Other 26. Valve Seat Cutter Set Parts List PART No. PART NAME Q’TY REMARKS 5SL-92110-70 CUTTER, INT 1 27.0 × 60° 5SL-92110-80 CUTTER, INT 2 27.0 × 90° 5SL-92110-90 CUTTER, INT 3 27.0 × 120° 5SL-92120-70 CUTTER, EXT 1 25.0 ×...

  • Page 44: Installation Precautions

    Installation Precautions NOTE: Please check next point for setting up your motorcycle. 3-1 Checking the Valve Seats The following procedure applies to all valves and valve seats. Eliminate : • lcarbon deposits (from the valve face and valve seat) Check : •...
  • Page 45 4. Lap : • lvalve face • lvalve seat NOTE: After replacing the cylinder head or the valve and the valve guide, the valve seat and valve face should be lapped. a. Apply a coarse lapping compound (a) to the valve face. CAUTION : Do not let the lapping compound enter the gap between the valve stem and...

  • Page 46: Selecting The Crankshaft Bearing

    3-2 Selecting the crankshaft bearing 1. Read the crank journal size. 2. Read the crankcase journal size. (Read the size number on the rear wall of the engine mount boss on the lower casing) 3. (Casing size number) - (Crank journal size number) - 1 = (Bearing size number) 5 (Yellow) 5VY-11416-40...

  • Page 47: Selecting The Connecting Rod Bearing

    3-3 Selecting the connecting rod bearing 1. Read the crank pin size. (Look at web 1 of the crankshaft.) 2. Read the big end size of the connecting rod (stamped on the connecting rod cap). 3. Selecting the connecting rod bearing (Big end size number) - (Crank pin size number) = (Bearing size number) 4 (Green) 5VY-11656-30...
  • Page 48 Connecting rod installation precautions 1. Install the connecting rod bearing onto the connecting rod with the projection in alignment. Apply oil generously to the bearing surface. 2. For installation, the word "YAMAHA" or the letter "Y" facing leftward. 3. Apply a generous amount of oil or oil-diluted molybdenum grease to the threads and seating surfaces of the connecting bolts and to the connecting rod seating surface;...

  • Page 49: Installing The Piston, Piston Ring And Connecting Rod

    3-4 Installing the piston, piston ring, and connecting rod Mating positions of the second ring (installed with the T mark upward) and the side rail (downward) Mating position of side rail (upward) Side rail (upward) Spacer Side rail (downward) Install the oil ring Mating position of the top ring and spacer CAUTION :...
  • Page 50 When replacing a piston without dismantling the crankcase, insert the oil ring carefully. A larger cylinder inclination may let the side rail come off and become wedged between the cylinders. Take care not to damage the cylinder contact surface. - 46 -...

  • Page 51: Crankcase Installation

    3-5 Crankcase installation Tightening the bolt a. 1. Follow the tightening sequence from 1 to 10 and tighten to a torque of 196 Nm (2.0 kg•m) 2. Following the sequence, tighten the bolts one by one and then retighten to a torque of 19.6 Nm 3.

  • Page 52: Cylinder Head Tightening (Calibrated Wrench Tightening Method)

    3-6 Cylinder head tightening (calibrated wrench tightening method). 1. Temporarily tighten to 19.0 Nm (1.9 kgf•m) before tightening fully. 2. Following the tightening sequence, tighten to 67.0 Nm (6.8 kgf•m). 3. After tightening the nuts, tighten the M6 bolts to 12 Nm (1.2 kgf•m). CAUTION : The figures 1 to 10 indicate the tightening sequence.

  • Page 53: Camshaft Installation

    3-7 Camshaft installation Timing matching Timing matching mark Timing matching mark - 49 -...

  • Page 54: Cam Chain Tensioner Installation

    3-8 Cam chain tension device installation To match the valve timing, use the oval holes in the standard sprocket. Install the tension device with its installation direction mark pointing upward. Up Side For installation, push back the rod, which actuates the guide and set the stopper as shown.

  • Page 55: Engine Mounting

    3-9 Engine mounting 1. Temporarily fit g BOLT, ENG. ADJ. to the frame. 2. Place the engine on the mounting location of the frame and temporarily fit e BOLT. 3. Temporarily fit cd BOSS, ENG. MOUNT on the frame and temporarily fit ab BOLT. 4.

  • Page 56: Front Axle Installation

    3-10 Front axle installation 1. Insert the front wheel axle on the right side and tighten b BOLT, FLG to 85 Nm on the left side. 2. Without preliminary tightening, fully tighten the bolts in the sequence pinch bolt 2, pinch bolt 1 and pinch bolt 2 to 10 Nm.
  • Page 57 TIGHTENING TORQUE LIST Engine Thread dia. × Tightening Point Part No. Part Name Tightening torque Nm (kgf•m) Q'ty Remarks pitch Turn-of-nut method: Retighten to Apply oil to thread and Cylinder head tightening 90176-10075 M10 × 1,25 135±5 degrees after tightening to seating surface.
  • Page 58 Engine Thread dia. × Tightening Point Part No. Part Name Tightening torque Nm (kgf•m) Q'ty Remarks pitch Crankcase cover 1 installation 90109-06031 Bolt M6 × 1,0 12±2 (1,2±0,2) ACM cover Crankcase cover 1 installation 92014-08035 Bolt, button head M8 × 1,25 20±2 (2,0±0,2) ACM cover Bolt, hexagonal socket...
  • Page 59 Chassis Thread dia. × Tightening Point Part No. Part Name Tightening torque Nm (kgf•m) Q'ty Remarks pitch Engine mounting: Cylinder head 95024-10045 Bolt M10 × 1,25 45±2 (4,5±0,2) (left) tightening Engine mounting: Cylinder head 95024-10040 Bolt M10 × 1,25 45±2 (4,5±0,2) (right) tightening Engine mounting: Crankcase top 90179-10696...

  • Page 60: Headlight Cord Wiring Diagram

    - 56 -...

  • Page 61: 2004 Yzf-R1 Wiring Diagram

    2004 YZF-R1 Wiring Diagram - 57 -...
  • Page 62 YEC CO.,LTD. 3622-8 Nishikaizuka. Iwata. Shizuoka. 438-0026 Japan Tel.: +81 – (0538)37–4488 Fax: +81 – (0538)37–6186...

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Yzf-r1 2004

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