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Yamaha R1 2004 ServiceManual

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    							EAS00010
    YZF-R1S / YZF-R1SC
    SERVICE MANUAL
    2003 by Yamaha Motor
    Corporation, U.S.A.
    First edition, December 2003
    All rights reserved. Any reproduction
    or unauthorized use without the written
    permission of Yamaha Motor Corporation,
    U.S.A. is expressly prohibited.
    Printed in U.S.A.
    P / N LIT-11616-17-55 
    						
    							NOTE:
    WARNING
    CAUTION:
    EAS00030
    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.
    This model has been designed and manufactured to perform within certain specifications in regard to
    performance and emissions. Proper service with the correct tools is necessary to ensure that the ve-
    hicle will operate as designed. If there is any question about a service procedure, it is imperative that
    you contact a Yamaha dealer for any service information changes that apply to this model. This policy
    is intended to provide the customer with the most satisfaction from his vehicle and to conform to federal
    environmental quality objectives.
    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.
    This Service Manual contains information regarding periodic maintenance to the emission control
    system. Please read this material carefully.
    Designs and specifications are subject to change without notice.
    EAS00040
    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. 
    						
    							12
    4
    8
    3
    5
    6
    7
    EAS00007
    HOW TO USE THIS MANUAL
    This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive
    explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid
    out with the individual steps in sequential order.
    1 The manual is divided into chapters. An abbreviation and symbol in the upper right corner of each
    page indicate the current chapter.
    Refer to “SYMBOLS”.
    2 Each chapter is divided into sections. The current section title is shown at the top of each page,
    except in Chapter 3 (“PERIODIC CHECKS AND ADJUSTMENTS”), where the sub-section title(s) ap-
    pears.
    3 Sub-section titles appear in smaller print than the section title.
    4 To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each
    removal and disassembly section.
    5 Numbers are given in the order of the jobs in the exploded diagram. A circled number indicates a
    disassembly step.
    6 Symbols indicate parts to be lubricated or replaced.
    Refer to “SYMBOLS”.
    7 A job instruction chart accompanies the exploded diagram, providing the order of jobs, names of
    parts, notes in jobs, etc.
    8 Jobs requiring more information (such as special tools and technical data) are described sequen-
    tially. 
    						
    							22
    1
    3
    5
    7
    9
    2
    4
    8
    6
    2425
    2321
    192018
    161715
    1413
    1112
    10
    GEN
    INFOSPEC
    ENG
    FI ELECCOOL CHK
    ADJ
    TRBL
    SHTG
    CHAS
    EAS00008
    SYMBOLS
    The following symbols are not relevant to every
    vehicle.
    Symbols 
    1 to 9 indicate 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.
    10Serviceable with engine mounted
    11Filling fluid
    12Lubricant
    13Special tool
    14Tightening torque
    15Wear limit, clearance
    16Engine speed
    17Electrical data
    Symbols 18 to 23 in the exploded diagrams indi-
    cate the types of lubricants and lubrication
    points.
    18Engine oil
    19Gear oil
    20Molybdenum-disulfide oil
    21Wheel-bearing grease
    22Lithium-soap- based grease
    23Molybdenum-disulfide grease
    Symbols 24 to 25 in the exploded diagrams indi-
    cate the following.
    24Apply locking agent (LOCTITE)
    25Replace the part 
    						
    							GENERAL INFORMATION
    SPECIFICATIONS
    PERIODIC CHECKS AND 
    ADJUSTMENTS
    CHASSIS
    ENGINE
    COOLING SYSTEM
    FUEL INJECTION SYSTEM
    ELECTRICAL SYSTEM
    TROUBLESHOOTING
    GEN
    INFO
    1
    SPEC2
    3
    ENG
    4
    COOL
    5
    FI
    6
    CHAS
    7
    ELEC8
    TRBL
    SHTG
    9
    CHK
    ADJ
    EAS00012
    TABLE OF CONTENTS 
    						
    							CHAPTER 1
    GENERAL INFORMATION
    MOTORCYCLE IDENTIFICATION1-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
    VEHICLE IDENTIFICATION NUMBER 1-1. . . . . . . . . . . . . . . . . . . . . . . . 
    MODEL LABEL 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
    FEATURES1-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
    INSTRUMENT FUNCTIONS 1-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
    IMPORTANT INFORMATION1-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
    PREPARATION FOR REMOVAL AND DISASSEMBLY 1-6. . . . . . . . . 
    REPLACEMENT PARTS 1-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
    GASKETS,  OIL SEALS AND O-RINGS 1-6. . . . . . . . . . . . . . . . . . . . . . . 
    LOCK WASHERS / PLATES AND COTTER PINS 1-7. . . . . . . . . . . . . . 
    BEARINGS AND OIL SEALS 1-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
    CIRCLIPS 1-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
    CHECKING THE CONNECTIONS1-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
    SPECIAL TOOLS1-9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
    CHAPTER 2
    SPECIFICATIONS
    GENERAL SPECIFICATIONS2-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
    ENGINE SPECIFICATIONS2-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
    CHASSIS SPECIFICATIONS2-11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
    ELECTRICAL SPECIFICATIONS2-15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
    CONVERSION TABLE2-18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
    GENERAL TIGHTENING TORQUE SPECIFICATIONS2-18 . . . . . . . . . . . . 
    TIGHTENING TORQUES2-19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
    ENGINE TIGHTENING TORQUES 2-19. . . . . . . . . . . . . . . . . . . . . . . . . . . 
    CHASSIS TIGHTENING TORQUES 2-23. . . . . . . . . . . . . . . . . . . . . . . . . . 
    LUBRICATION POINTS AND LUBRICANT TYPES2-25 . . . . . . . . . . . . . . . 
    ENGINE 2-25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
    CHASSIS 2-26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
    COOLING SYSTEM DIAGRAMS2-27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
    ENGINE OIL LUBRICATION CHART2-29 . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
    						
    							LUBRICATION DIAGRAMS2-30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
    CABLE ROUTING2-35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
    CHAPTER 3
    PERIODIC CHECKS AND ADJUSTMENTS
    INTRODUCTION3-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
    PERIODIC MAINTENANCE CHART FOR THE EMISSION
    CONTROL SYSTEM3-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
    GENERAL MAINTENANCE AND LUBRICATION CHART3-1 . . . . . . . . . 
    SEATS3-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
    FUEL TANK3-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
    REMOVING THE FUEL TANK 3-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
    REMOVING THE FUEL PUMP 3-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
    INSTALLING THE FUEL PUMP 3-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
    INSTALLING THE FUEL TANK 3-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
    COWLINGS3-7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
    FRONT COWLING AND SIDE COWLINGS 3-7. . . . . . . . . . . . . . . . . . . 
    REAR COWLING 3-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
    REMOVAL 3-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
    INSTALLATION 3-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
    AIR FILTER CASE3-10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
    ENGINE3-11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
    ADJUSTING THE VALVE  CLEARANCE 3-11. . . . . . . . . . . . . . . . . . . . . . 
    SYNCHRONIZING THE THROTTLE BODIES 3-17. . . . . . . . . . . . . . . . . 
    ADJUSTING THE EXHAUST GAS VOLUME 3-19. . . . . . . . . . . . . . . . . . 
    ADJUSTING THE ENGINE IDLING SPEED 3-21. . . . . . . . . . . . . . . . . . . 
    ADJUSTING THE THROTTLE CABLE FREE PLAY 3-22. . . . . . . . . . . . 
    CHECKING THE SPARK PLUGS 3-23. . . . . . . . . . . . . . . . . . . . . . . . . . . . 
    MEASURING THE COMPRESSION PRESSURE 3-24. . . . . . . . . . . . . . 
    CHECKING THE ENGINE OIL LEVEL 3-26. . . . . . . . . . . . . . . . . . . . . . . . 
    CHANGING THE ENGINE OIL 3-28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
    MEASURING THE ENGINE OIL PRESSURE 3-29. . . . . . . . . . . . . . . . . 
    ADJUSTING THE CLUTCH CABLE FREE PLAY 3-31. . . . . . . . . . . . . . . 
    REPLACING THE AIR FILTER ELEMENT 3-32. . . . . . . . . . . . . . . . . . . . 
    CHECKING THE FUEL AND BREATHER HOSES 3-33. . . . . . . . . . . . . 
    CHECKING THE CRANKCASE BREATHER HOSE 3-34. . . . . . . . . . . . 
    CHECKING THE EXHAUST SYSTEM 3-35. . . . . . . . . . . . . . . . . . . . . . . . 
    ADJUSTING THE EXUP CABLES 3-36. . . . . . . . . . . . . . . . . . . . . . . . . . . 
    CHECKING THE COOLANT LEVEL 3-37. . . . . . . . . . . . . . . . . . . . . . . . . . 
    CHECKING THE COOLING SYSTEM 3-38. . . . . . . . . . . . . . . . . . . . . . . . 
    CHANGING THE COOLANT 3-39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
    						
    							CHASSIS3-42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
    ADJUSTING THE FRONT BRAKE 3-42. . . . . . . . . . . . . . . . . . . . . . . . . . . 
    ADJUSTING THE REAR BRAKE 3-43. . . . . . . . . . . . . . . . . . . . . . . . . . . . 
    CHECKING THE BRAKE FLUID LEVEL 3-44. . . . . . . . . . . . . . . . . . . . . . 
    ADJUSTING THE REAR BRAKE LIGHT SWITCH 3-45. . . . . . . . . . . . . 
    CHECKING THE FRONT AND REAR BRAKE PADS 3-45. . . . . . . . . . . 
    CHECKING THE FRONT AND REAR BRAKE HOSES 3-46. . . . . . . . . 
    BLEEDING THE HYDRAULIC BRAKE SYSTEM 3-47. . . . . . . . . . . . . . . 
    ADJUSTING THE SHIFT PEDAL 3-48. . . . . . . . . . . . . . . . . . . . . . . . . . . . 
    ADJUSTING THE DRIVE CHAIN SLACK 3-49. . . . . . . . . . . . . . . . . . . . . 
    LUBRICATING THE DRIVE CHAIN 3-50. . . . . . . . . . . . . . . . . . . . . . . . . . 
    CHECKING AND ADJUSTING THE STEERING HEAD 3-51. . . . . . . . . 
    CHECKING THE FRONT FORK 3-53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
    ADJUSTING THE FRONT FORK LEGS 3-54. . . . . . . . . . . . . . . . . . . . . . 
    ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY 3-56. . . . . 
    CHECKING THE TIRES 3-58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
    CHECKING THE WHEELS 3-60. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
    CHECKING AND LUBRICATING THE CABLES 3-61. . . . . . . . . . . . . . . 
    LUBRICATING THE LEVERS AND PEDALS 3-61. . . . . . . . . . . . . . . . . . 
    LUBRICATING THE SIDESTAND 3-61. . . . . . . . . . . . . . . . . . . . . . . . . . . . 
    LUBRICATING THE REAR SUSPENSION 3-61. . . . . . . . . . . . . . . . . . . . 
    ELECTRICAL SYSTEM3-62 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
    CHECKING AND CHARGING THE BATTERY 3-62. . . . . . . . . . . . . . . . . 
    CHECKING THE FUSES 3-67. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
    REPLACING THE HEADLIGHT BULBS 3-69. . . . . . . . . . . . . . . . . . . . . . 
    ADJUSTING THE HEADLIGHT BEAMS 3-70. . . . . . . . . . . . . . . . . . . . . . 
    CHAPTER 4
    CHASSIS
    FRONT WHEEL AND BRAKE DISCS4-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . 
    REMOVING THE FRONT WHEEL 4-3. . . . . . . . . . . . . . . . . . . . . . . . . . . 
    CHECKING THE FRONT WHEEL 4-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . 
    CHECKING THE BRAKE DISCS 4-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
    INSTALLING THE FRONT WHEEL 4-6. . . . . . . . . . . . . . . . . . . . . . . . . . . 
    ADJUSTING THE FRONT WHEEL STATIC BALANCE 4-7. . . . . . . . . 
    REAR WHEEL AND BRAKE DISC4-9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
    REAR WHEEL 4-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
    REAR BRAKE DISC AND REAR WHEEL SPROCKET 4-10. . . . . . . . . 
    REMOVING THE REAR WHEEL 4-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
    CHECKING THE REAR WHEEL 4-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
    CHECKING THE REAR WHEEL DRIVE HUB 4-13. . . . . . . . . . . . . . . . . 
    CHECKING AND REPLACING THE REAR WHEEL 
    SPROCKET 4-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
    INSTALLING THE REAR WHEEL 4-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . 
    ADJUSTING THE REAR WHEEL STATIC BALANCE 4-14. . . . . . . . . . .  
    						
    							FRONT AND REAR BRAKES4-15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
    FRONT BRAKE PADS 4-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
    REAR BRAKE PADS 4-16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
    REPLACING THE FRONT BRAKE PADS 4-18. . . . . . . . . . . . . . . . . . . . . 
    REPLACING THE REAR BRAKE PADS 4-20. . . . . . . . . . . . . . . . . . . . . . 
    FRONT BRAKE MASTER CYLINDER 4-22. . . . . . . . . . . . . . . . . . . . . . . . 
    REAR BRAKE MASTER CYLINDER 4-25. . . . . . . . . . . . . . . . . . . . . . . . . 
    DISASSEMBLING  THE FRONT BRAKE MASTER 
    CYLINDER 4-27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
    DISASSEMBLING  THE REAR BRAKE MASTER 
    CYLINDER 4-27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
    CHECKING THE FRONT AND REAR BRAKE MASTER 
    CYLINDERS 4-28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
    ASSEMBLING  AND INSTALLING THE FRONT BRAKE 
    MASTER CYLINDER 4-29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
    ASSEMBLING  THE REAR BRAKE MASTER CYLINDER 4-31. . . . . . . 
    FRONT BRAKE CALIPERS 4-33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
    REAR BRAKE CALIPER 4-35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
    DISASSEMBLING  THE FRONT BRAKE CALIPERS 4-37. . . . . . . . . . . 
    DISASSEMBLING  THE REAR BRAKE CALIPER 4-38. . . . . . . . . . . . . . 
    CHECKING THE FRONT AND REAR BRAKE CALIPERS 4-39. . . . . . 
    ASSEMBLING  AND INSTALLING THE FRONT BRAKE 
    CALIPERS 4-40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
    ASSEMBLING  AND INSTALLING THE REAR 
    BRAKE CALIPER 4-42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
    FRONT FORK4-44 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
    FRONT FORK LEGS 4-44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
    REMOVING THE FRONT FORK LEGS 4-47. . . . . . . . . . . . . . . . . . . . . . . 
    DISASSEMBLING  THE FRONT FORK LEGS 4-48. . . . . . . . . . . . . . . . . 
    CHECKING THE FRONT FORK LEGS 4-49. . . . . . . . . . . . . . . . . . . . . . . 
    ASSEMBLING  THE FRONT FORK LEGS 4-50. . . . . . . . . . . . . . . . . . . . . 
    INSTALLING THE FRONT FORK LEGS 4-55. . . . . . . . . . . . . . . . . . . . . . 
    HANDLEBARS4-56 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
    REMOVING THE HANDLEBARS 4-58. . . . . . . . . . . . . . . . . . . . . . . . . . . . 
    CHECKING THE HANDLEBARS 4-58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
    INSTALLING THE HANDLEBARS 4-58. . . . . . . . . . . . . . . . . . . . . . . . . . . 
    CHECKING THE STEERING DAMPER 4-60. . . . . . . . . . . . . . . . . . . . . . . 
    STEERING HEAD4-61 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
    UNDER BRACKET 4-61. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
    REMOVING THE UNDER BRACKET 4-63. . . . . . . . . . . . . . . . . . . . . . . . . 
    CHECKING THE STEERING HEAD 4-63. . . . . . . . . . . . . . . . . . . . . . . . . . 
    INSTALLING THE STEERING HEAD 4-64. . . . . . . . . . . . . . . . . . . . . . . . .  
    						
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