Yamaha YZF-R1 2004 Operating and installation instructions

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

Yamaha Motor Co., Ltd.
FOREWORD
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

NOTE:
WARNING
CAUTION:
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.
Repair and maintenance work attempted by anyone without this knowledge is likely to render the ve-
hicle unsafe and unfit for use.
Yamaha Motor Company, Ltd. is continually striving to improve 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.
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR
SAFETY IS INVOLVED!
Failure to follow WARNING instructions could result in severe injury or death to
the motorcycle operator, a bystander or a person checking or repairing the mo-
torcycle.
A CAUTION indicates special precautions that must be taken to avoid damage
to the motorcycle.
NOTE: A NOTE provides key information to make procedures easier or clearer.

22
1
3
5
7
9
2
4
8
6
24 25
2321
19 2018
16 1715
1413
11 12
10
GEN
INFO SPEC
ENG
FI ELEC
COOL
CHK
ADJ
TRBL
SHTG
CHAS
EAS00008
SYMBOLS
The following symbols are not relevant to every
vehicle.
Symbols 1to 9indicate the subject of each
chapter.
1General information
2Specifications
3Periodic checks and adjustments
4Chassis
5Engine
6Cooling system
7Fuel injection system
8Electrical system
9Troubleshooting
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-bearing grease
22 Lithium-soap-based grease
23 Molybdenum-disulfide grease
Symbols 24 to 25 in the exploded diagrams indi-
cate the following.
24 Apply locking agent (LOCTITE)
25 Replace the part

CONTENTS
GENERAL INFORMATION
MOTORCYCLE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
VEHICLE IDENTIFICATION NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . 1
MODEL LABEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
SPECIFICATIONS
GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
ENGINE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
CHASSIS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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

1-1
MOTORCYCLE IDENTIFICATION GEN
INFO
EAS00014
GENERAL INFORMATION
MOTORCYCLE IDENTIFICATION
EAS00017
VEHICLE IDENTIFICATION NUMBER
The vehicle identification number 1is stamped
into the right side of the steering head pipe.
EAS00018
MODEL LABEL
The model label 1is affixed to the frame. This
information will be needed to order spare parts.
1

2-1
GENERAL SPECIFICATIONS SPEC
SPECIFICATIONS
GENERAL SPECIFICATIONS
Item Standard Limit
Model code 5VY1 (EUR), 5VY2 (FRA), 5VY3 (AUS) SSS
Dimensions
Overall length
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

2-2
ENGINE SPECIFICATIONS SPEC
ENGINE SPECIFICATIONS
Item Standard Limit
Engine
Engine type
Displacement
Cylinder arrangement
Bore stroke
Compression ratio
Engine idling speed
Vacuum pressure at engine idling
speed
Standard compression pressure
(at sea level)
Liquid-cooled, 4-stroke, DOHC
998 cm3(60.90 cu.in)
Forward-inclined parallel 4-cylinder
77.0 53.6 mm (3.03 2.11 in)
12.4 : 1
1,150 X1,250 r/min
22 kPa (165 mmHg, 6.5 inHg)
1,480 kPa (14.80 kg/cm2,14.80 bar,
210.5 psi) at 350 r/min
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
Fuel
Recommended 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 or SAE10W30SE
API service SE, SF, SG type or higher
3.8 L (3.35 Imp qt, 4.02 US qt)
2.9 L (2.55 Imp qt, 3.07 US qt)
3.1 L (2.73 Imp qt, 3.28 US qt)
230 kPa at 5,000 r/min
(2.3 kg/cm2at 5,000 r/min)
(2.3 bar at 5,000 r/min)
(32.7 psi at 5,000 r/min)
100_C (212_F)
600 X680 kPa (6.0 X6.8 kg/cm2,
6.0 X6.8 bar, 87.0 X98.6 psi)
SSS
SSS
SSS
SSS
SSS
3

2-3
ENGINE SPECIFICATIONS SPEC
Item Standard Limit
Oil filter
Oil filter type
Bypass valve opening pressure
Paper
80 X120 kPa (0.8 X1.2 kg/cm2,
0.8 X1.2 bar, 11.6 X17.4 psi)
SSS
SSS
Oil pump
Oil pump type
Inner-rotor-to-outer-rotor-tip
clearance
Outer-rotor-to-oil-pump-housing
clearance
Trochoid
0.01 X0.10 mm
(0.0004 X0.0039 in)
0.09 X0.15 mm
(0.00035 X0.0059 in)
SSS
0.18 mm
(0.0071 in)
0.22 mm
(0.0087 in)
Cooling system
Radiator capacity
Radiator cap 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 X137 kPa (1.08 X1.37 kg/cm2,
1.0 X1.3 bar, 15.6 X19.9 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 mm
(0.006 in)
Starting system type Electric starter
Spark plugs
Model (manufacturer) quantity
Spark plug gap
CR9EK (NGK) 4
0.6 X0.7 mm (0.0236 X0.0276 in)
SSS
SSS
Cylinder head
Volume
Max. warpage
12.5 X13.1 cm3(0.76 X0.80 cu.in)
SSS
SSS
0.10 mm
(0.0039 in)
4

2-4
ENGINE SPECIFICATIONS SPEC
Item Standard Limit
Camshafts
Drive system
Camshaft cap inside diameter
Camshaft journal diameter
Camshaft-journal-to-camshaft-
cap clearance
Intake camshaft lobe dimensions
Measurement A
Measurement B
Exhaust camshaft lobe dimensions
Measurement A
Measurement B
Max. camshaft runout
Chain drive (right)
22.500 X22.521 mm (0.8858 X0.8867 in)
22.459 X22.472 mm (0.8842 X0.8847 in)
0.028 X0.062 mm (0.0011 X0.0024 in)
32.85 X32.95 mm (1.293 X1.297 in)
25.14 X25.24 mm (0.990 X0.994 in)
30.75 X30.85 mm (1.211 X1.215 in)
23.09 X23.19 mm (0.909 X0.913 in)
SSS
SSS
SSS
SSS
32.75 mm
(1.289 in)
25.04 mm
(0.986 in)
30.65 mm
(1.207 in)
22.99 mm
(0.905 in)
0.03 mm
(0.0012 in)
5