Yamaha R1 2004 ServiceManual
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3-34 CHECKING THE FUEL AND BREATHER HOSES / CHECKING THE CRANKCASE BREATHER HOSECHK ADJ CAUTION: CAUTION: CAUTION: 3. Install: fuel tank Refer to “FUEL TANK”. rider seat Refer to “SEATS”. To install the fuel tank, check that the breath- er hose is not folded or pinched by the fuel tank. EAS00098 CHECKING THE CRANKCASE BREATHER HOSE 1. Remove: rider seat Refer to “SEATS”. fuel tank Refer to “FUEL TANK”. 2. Check: crankcase breather hose 1 Cracks / damage Replace. Loose connection Connect properly. Make sure the crankcase breather hose is routed correctly. 3. Install: fuel tank Refer to “FUEL TANK”. rider seat Refer to “SEATS”. To install the fuel tank, check that the breath- er hose is not folded or pinched by the fuel tank.
3-35 CHECKING THE EXHAUST SYSTEM CHK ADJ WARNING NOTE: EAS00099 CHECKING THE EXHAUST SYSTEM The following procedure applies to all of the ex- haust pipes and gaskets. Do not touch the muffler bracket until the ex- haust system has cooled. 1. Check: exhaust pipe 1 exhaust valve pipe 2 muffler 3 Cracks / damage Replace. gaskets 4 Exhaust gas leaks Replace. 2. Check: tightening torque Exhaust pipe nut 5 20 Nm (2.0 mkg, 14 ftlb) Exhaust pipe and exhaust valve pipe bolt 6 10 Nm (1.0 mkg, 7.2 ftlb) Catalyst pipe assembly bolt 7 20 Nm (2.0mkg, 14 ftlb) Catalyst pipe assembly and muffler bolt 8 20 Nm (2.0 mkg, 14 ftlb) Muffler cover 9 10 Nm (1.0 mkg, 7.2 ftlb) Install the EXUP cable in parallel without twist- ing its upper 10 and lower sides 11. black metal 10 is upper. white metal 11 is lower.
3-36 ADJUSTING THE EXUP CABLES CHK ADJ EAS00101 ADJUSTING THE EXUP CABLES 1. Remove: bottom cowlings Refer to “COWLINGS”. 2. Remove: EXUP valve pulley cover 1 3. Check: EXUP system operation a. Turn the main switch ON. b. Check that the EXUP valve operates properly. 4. Check: EXUP cable free play (at the EXUP valve pulley) a + b Maximum EXUP cable free play (at the EXUP valve pulley) Less than 4 mm (0.16 in) 5. Adjust: EXUP cable free play a. Turn the main switch to “ON”. b. Check the EXUP pulley position. c. Projection of the EXUP pulley position is be- tween 1 and 2. d. Loosen the both locknuts 3. e. Turn the both adjusting nuts 4 in or out. f. Tighten the both locknuts. 6. Install: EXUP valve pulley cover EXUP valve pulley cover bolt 10 Nm (1.0 mkg, 7.2 ftlb)
3-37 ADJUSTING THE EXUP CABLES / CHECKING THE COOLANT LEVELCHK ADJ NOTE: CAUTION: NOTE: 7. Install: bottom cowlings Refer to “COWLINGS”. EAS00102 CHECKING THE COOLANT LEVEL 1. Stand the motorcycle on a level surface. Place the motorcycle on a suitable stand. Make sure the motorcycle is upright. 2. Check: coolant level The coolant level should be between the maximum level mark a and minimum level mark b. Below the minimum level mark Add the recommended coolant to the proper level. Adding water instead of coolant lowers the antifreeze content of the coolant. If water is used instead of coolant check, and if nec- essary, correct the antifreeze concentra- tion of the coolant. Use only distilled water. However, if dis- tilled water is not available, soft water may be used. 3. Start the engine, warm it up for several min- utes, and then turn it off. 4. Check: coolant level Before checking the coolant level, wait a few minutes until it settles.
3-38 CHECKING THE COOLING SYSTEM CHK ADJ EAS00104 CHECKING THE COOLING SYSTEM 1. Remove: bottom cowlings side cowlings Refer to “COWLINGS”. 2. Check: radiator 1 radiator inlet hose 2 radiator outlet hose 3 oil cooler 4 oil cooler inlet hose 5 oil cooler outlet hose 6 water jacket joint 7 water jacket joint inlet hose 8 water pump inlet pipe 9 water pump outlet pipe 10 Cracks / damage Replace. Refer to “COOLING SYSTEM” in chapter 6. 3. Install: side cowlings bottom cowling Refer to “COWLINGS”.
3-39 CHANGING THE COOLANT CHK ADJ CAUTION: EAS00105 CHANGING THE COOLANT 1. Remove: bottom cowlings side cowlings Refer to “COWLINGS”. rider seat Refer to “SEATS”. 2. Remove: coolant reservoir tank coolant reservoir hose 3. Disconnect: coolant reservoir cap 1 4. Drain: coolant (from the coolant reservoir tank) 5. Remove: radiator cap 1 A hot radiator is under pressure. Therefore, do not remove the radiator cap when the en- gine is hot. Scalding hot fluid and steam may be blown out, which could cause serious in- jury. When the engine has cooled, open the radiator cap as follows: Place a thick rag or a towel over the radiator cap and slowly turn the radiator cap coun- terclockwise toward the detent to allow any residual pressure to escape. When the his- sing sound has stopped, press down on the radiator cap and turn it counterclockwise to remove. The following procedure applies to all of the coolant drain bolts and copper washers. 6. Remove: coolant drain bolts 1 (along with the copper washers)
3-40 CHANGING THE COOLANT CHK ADJ 10 Nm (1.0 mkg, 7.2 ftlb) WARNING 7. Drain: coolant (water pump inlet pipe and outlet pipe) 8. Check: copper washers 1 New 9. Install: coolant drain bolts 2 (with copper washers) 10. Install: coolant reservoir tank 11. Connect: coolant reservoir hose 12. Fill: cooling system (with the specified amount of the recom- mended coolant) Recommended antifreeze High-quality ethylene glycol antifreeze containing corrosion inhibitors for aluminum engines Mixing ratio 1:1 (antifreeze:water) Quantity Total amount 2.51 L (2.21 Imp qt, 2.65 US qt) Coolant reservoir capacity 0.25 L (0.22 Imp qt, 0.26 US qt) Handling notes for coolant Coolant is potentially harmful and should be handled with special care. If coolant splashes in your eyes, thorough- ly wash them with water and consult a doc- tor. If coolant splashes on your clothes, quick- ly wash it away with water and then with soap and water. If coolant is swallowed, induce vomiting and get immediate medical attention.
3-41 CHANGING THE COOLANT CHK ADJ CAUTION: NOTE: Adding water instead of coolant lowers the antifreeze content of the coolant. If water is used instead of coolant check, and if nec- essary, correct the antifreeze concentra- tion of the coolant. Use only distilled water. However, if dis- tilled water is not available, soft water may be used. If coolant comes into contact with painted surfaces, immediately wash them with wa- ter. Do not mix different types of antifreeze. 13. Install: radiator cap 14. Fill: coolant reservoir tank (with the recommended coolant to the maxi- mum level mark a) 15. Install: coolant reservoir cap 16. Start the engine, warm it up for several min- utes, and then stop it. 17. Check: coolant level Refer to “CHECKING THE COOLANT LEV- EL”. Before checking the coolant level, wait a few minutes until the coolant has settled. 18. Install: rider seat Refer to “SEATS”. bottom cowlings side cowlings Refer to “COWLINGS”.
3-42 ADJUSTING THE FRONT BRAKE CHK ADJ NOTE: a ac b WARNING CAUTION: EAS00107 CHASSIS ADJUSTING THE FRONT BRAKE 1. Adjust: brake lever position (distance a from the throttle grip to the brake lever) While pushing the brake lever forward, turn the adjusting dial 1 until the brake lever is in the de- sired position. Direction Distance is the largest. DirectionDistance is the smallest. After adjusting the brake lever position, make sure the pin on the brake lever holder is firmly inserted in the hole in the adjust- ing dial. A soft or spongy feeling in the brake lever can indicate the presence of air in the brake system. Before the vehicle is operated, the air must be removed by bleeding the brake system. Air in the brake system will consid- erably reduce in loss of control and possi- bly an accident. Therefore, check and if necessary, bleed the brake system. After adjusting the brake lever position, make sure there is no brake drag.
3-43 ADJUSTING THE REAR BRAKE CHK ADJ a b WARNING WARNING CAUTION: EAS00110 ADJUSTING THE REAR BRAKE 1. Adjust: brake pedal position a. Loosen the locknut 1. b. Turn the adjusting bolt 2 in direction a or b until the specified brake pedal position is ob- tained. Direction Brake pedal is raised. DirectionBrake pedal is lowered. After adjusting the brake pedal position, check that the end of the adjusting bolt c is visible through the hole d. c. Tighten the locknut 1 to specification. Locknut 16 Nm (1.6 mkg, 12 ftlb) A soft or spongy feeling in the brake pedal can indicate the presence of air in the brake system. Before the vehicle is operated, the air must be removed by bleeding the brake system. Air in the brake system will consid- erably reduce braking performance and could result in loss of control and possibly an accident. Therefore, check and, if neces- sary, bleed the brake system. After adjusting the brake pedal position, make sure there is no brake drag. 2. Adjust: rear brake light switch Refer to “ADJUSTING THE REAR BRAKE LIGHT SWITCH”.