Yamaha R1 2004 ServiceManual
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3-54 ADJUSTING THE FRONT FORK LEGS CHK ADJ WARNING CAUTION: a b CAUTION: EAS00155 ADJUSTING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. Always adjust both front fork legs evenly. Uneven adjustment can result in poor han- dling and loss of stability. Securely support the motorcycle so that there is no danger of it falling over. Spring preload Grooves are provided to indicate the ad- justment position. Never go beyond the maximum or mini- mum adjustment positions. 1. Adjust: spring preload a. Turn the adjusting bolt 1 in direction a or b. Direction Spring preload is increased (suspension is harder). Direction Spring preload is decreased (suspension is softer). Adjusting positions Minimum: 8 Standard: 4.5 Maximum: 1 Rebound damping Never go beyond the maximum or minimum adjustment positions.
3-55 ADJUSTING THE FRONT FORK LEGS CHK ADJ a b CAUTION: a b 1. Adjust: rebound damping a. Turn the adjusting screw 1 in direction a or b. Direction Rebound damping is increased (suspension is harder). Direction Rebound damping is decreased (suspension is softer). Adjusting positions Minimum: 26 clicks in direction b * Standard: 10 clicks in direction b * Maximum: 1 clicks in direction b * * with the adjusting screw fully turned-in direction a Compression damping Never go beyond the maximum or minimum adjustment positions. 1. Adjust: compression damping a. Turn the adjusting screw 1 in direction a or b. Direction Compression damping is increased (suspension is harder). Direction Compression damping is decreased (suspension is softer). Adjusting positions Minimum: 25 clicks in direction b * Standard: 10 clicks in direction b * Maximum: 1 clicks in direction b * * with the adjusting screw fully turned-in direction a
3-56 ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY CHK ADJ WARNING CAUTION: a b CAUTION: EAS00158 ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY Securely support the motorcycle so that there is no danger of it falling over. Spring preload Never go beyond the maximum or minimum adjustment positions. 1. Adjust: spring preload a. Adjust the spring preload with the special wrench and extension bar included in the owner’s tool kit. b. Turn the adjusting ring 1 in direction a or b. c. Align the desired position on the adjusting ring with the stopper 2. Direction Spring preload is increased (suspension is harder). Direction Spring preload is decreased (suspension is softer). Adjusting positions Minimum: 1 Standard: 4 Maximum: 9 Rebound damping Never go beyond the maximum or minimum adjustment positions.
3-57 ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY CHK ADJ a b CAUTION: a b 1. Adjust: rebound damping a. Turn the adjusting screw 1 in direction a or b. Direction Rebound damping is increased (suspension is harder). Direction Rebound damping is decreased (suspension is softer). Adjusting positions Minimum: 20 clicks in direction b * Standard: 17 clicks in direction b * Maximum: 1 clicks in direction b * * with the adjusting screw fully turned-in direction a Compression damping Never go beyond the maximum or minimum adjustment positions. 1. Adjust: compression damping a. Turn the adjusting screw 1 in direction a or b. Direction Compression damping is increased (suspension is harder). Direction Compression damping is decreased (suspension is softer). Adjusting positions Minimum: 20 clicks in direction b * Standard: 12 clicks in direction b * Maximum: 1 clicks in direction b * * with the adjusting screw fully turned-in direction a
3-58 CHECKING THE TIRES CHK ADJ WARNING WARNING EAS00162 CHECKING THE TIRES The following procedure applies to both of the tires. 1. Check: tire pressure Out of specification Regulate. The tire pressure should only be checked and regulated when the tire temperature equals the ambient air temperature. The tire pressure and the suspension must be adjusted according to the total weight (including cargo, rider, passenger and ac- cessories) and the anticipated riding speed. Operation of an overloaded motorcycle could cause tire damage, an accident or an injury. NEVER OVERLOAD THE MOTORCYCLE. Basic weight (with oil and a full fuel tank) 193 kg (425 lb) 194 kg (428 lb) for CAL Maximum load*202 kg (445 lb) 201 kg (443 lb) for CAL Cold tire pressureFrontRear Up to 90 kg load*250 kPa (2.5 kgf / cm2, 2.5 bar, 35.6 psi) 290 kPa (2.9 kgf / cm2, 2.9 bar, 41.3 psi) 90 kg maximum load*250 kPa (2.5 kgf / cm2, 2.5 bar, 35.6 psi) 290 kPa (2.9 kgf / cm2, 2.9 bar, 41.3 psi) High- speed riding250 kPa (2.5 kgf / cm2, 2.5 bar, 35.6 psi) 290 kPa (2.9 kgf / cm2, 2.9 bar, 41.3 psi) * Total weight of rider, passenger, cargo and ac- cessories It is dangerous to ride with a worn-out tire. When the tire tread reaches the wear limit, replace the tire immediately.
3-59 AB CHECKING THE TIRES CHK ADJ WARNING WARNING 2. Check: tire surfaces Damage / wear Replace the tire. Minimum tire tread depth 1.6 mm (0.06 in) 1Tire tread depth 2Sidewall 3Wear indicator Do not use a tubeless tire on a wheel de- signed only for tube tires to avoid tire fail- ure and personal injury from sudden defla- tion. When using a tube tire, be sure to install the correct tube. Always replace a new tube tire and a new tube as a set. To avoid pinching the tube, make sure the wheel rim band and tube are centered in the wheel groove. Patching a punctured tube is not recom- mended. If it is absolutely necessary to do so, use great care and replace the tube as soon as possible with a good quality re- placement. ATire BWheel Tube wheelTube tire only T beless wheelTube or tubelessTubeless wheeltire After extensive tests, the tires listed below have been approved by Yamaha Motor Co., Ltd. for this model. The front and rear tires should always be by the same manufacturer and of the same design. No guarantee con- cerning handling characteristics can be giv- en if a tire combination other than one ap- proved by Yamaha is used on this motorcycle.
3-60 CHECKING THE TIRES / CHECKING THE WHEELS CHK ADJ WARNING NOTE: WARNING NOTE: Front tire Manufacturer SizeModel DUNLOP120 / 70ZR 17 M / C (58W)D218FL MICHELIN120 / 70ZR 17 M / C (58W)Pilot POWER C Rear tire Manufacturer SizeModel DUNLOP190 / 50ZR 17 M / C (73W)D218L MICHELIN190 / 50ZR 17 M / C (73W)Pilot POWER G New tires have a relatively low grip on the road surface until they have been slightly worn. Therefore, approximately 100 km should be traveled at normal speed before any high-speed riding is done. For tires with a direction of rotation mark 1: Install the tire with the mark pointing in the direction of wheel rotation. Align the mark 2 with the valve installation point. EAS00168 CHECKING THE WHEELS The following procedure applies to both of the wheels. 1. Check: wheel Damage / out-of-round Replace. Never attempt to make any repairs to the wheel. After a tire or wheel has been changed or re- placed, always balance the wheel.
3-61 CHECKING AND LUBRICATING THE CABLES / LUBRICATING THE LEVERS AND PEDALS / LUBRICATING THE SIDESTAND / LUBRICATING THE REAR SUSPENSIONCHK ADJ WARNING NOTE: EAS00170 CHECKING AND LUBRICATING THE CABLES The following procedure applies to all of the in- ner and outer cables. Damaged outer cable may cause the cable to corrode and interfere with its movement. Re- place damaged outer cable and inner cables as soon as possible. 1. Check: outer cable Damage Replace. 2. Check: cable operation Rough movement Lubricate. Recommended lubricant Engine oil or a suitable cable lubricant Hold the cable end upright and pour a few drops of lubricant into the cable sheath or use a suit- able lubricating device. EAS00171 LUBRICATING THE LEVERS AND PEDALS Lubricate the pivoting point and metal-to-metal moving parts of the levers and pedals. Recommended lubricant Lithium-soap-based grease EAS00172 LUBRICATING THE SIDESTAND Lubricate the pivoting point and metal-to-metal moving parts of the sidestand. Recommended lubricant Lithium-soap-based grease EAS00174 LUBRICATING THE REAR SUSPENSION Lubricate the pivoting point and metal-to-metal moving parts of the rear suspension. Recommended lubricant Molybdenum-disulfide grease
3-62 CHECKING AND CHARGING THE BATTERY CHK ADJ WARNING CAUTION: EAS00178 ELECTRICAL SYSTEM CHECKING AND CHARGING THE BATTERY Batteries generate explosive hydrogen gas and contain electrolyte which is made of poi- sonous and highly caustic sulfuric acid. Therefore, always follow these preventive measures: Wear protective eye gear when handling or working near batteries. Charge batteries in a well-ventilated area. Keep batteries away from fire, sparks or open flames (e.g., welding equipment, lighted cigarettes). DO NOT SMOKE when charging or han- dling batteries. KEEP BATTERIES AND ELECTROLYTE OUT OF REACH OF CHILDREN. Avoid bodily contact with electrolyte as it can cause severe burns or permanent eye injury. FIRST AID IN CASE OF BODILY CONTACT: EXTERNAL Skin – Wash with water. Eyes – Flush with water for 15 minutes and get immediate medical attention. INTERNAL Drink large quantities of water or milk fol- lowed with milk of magnesia, beaten egg or vegetable oil. Get immediate medical atten- tion. This is a sealed battery. Never remove the sealing caps because the balance between cells will not be maintained and battery per- formance will deteriorate. Charging time, charging amperage and charging voltage for an MF battery are dif- ferent from those of conventional batter- ies. The MF battery should be charged as explained in the charging method illustra- tions. If the battery is overcharged, the electrolyte level will drop considerably. Therefore, take special care when charging the battery.
3-63 Relationship between the open-circuit voltage and the charging time at 20C Open-circuit voltage (V) These values vary with the temperature, the condition of the battery plates, and the electrolyte level. 13.0 12.5 12.0 11.5 5 6.5 10 Charging time (hours) Ambient temperature 20C Open-circuit voltage (V) Charging condition of the battery (%) CHECKING AND CHARGING THE BATTERY CHK ADJ NOTE: CAUTION: NOTE: Since MF batteries are sealed, it is not possible to check the charge state of the battery by mea- suring the specific gravity of the electrolyte. Therefore, the charge of the battery has to be checked by measuring the voltage at the battery terminals. 1. Remove: rider seat Refer to “SEATS”. 2. Disconnect: battery leads (from the battery terminals) First, disconnect the negative battery lead 1, and then the positive battery lead 2. 3. Remove: battery 4. Check: battery charge a. Connect a pocket tester to the battery termi- nals. Pocket tester 90890-03112, YU-3112 Positive tester probe positive battery terminal Negative tester probe negative battery terminal The charge state of an MF battery can be checked by measuring its open-circuit voltage (i.e., the voltage when the positive battery ter- minal is disconnected). No charging is necessary when the open-cir- cuit voltage equals or exceeds 12.8 V. b. Check the charge of the battery, as shown in the charts and the following example. Example c. Open-circuit voltage = 12.0 V d. Charging time = 6.5 hours e. Charge of the battery = 20 30%