Yamaha R1 2004 ServiceManual

							3-64
Charging
Ambient temperature 20C
Open-circuit voltage (V)
Check the open-circuit
voltage.Time (minutes)
CHECKING AND CHARGING THE BATTERY
CHK
ADJ
WARNING
CAUTION:
5. Charge:

battery
(refer to the appropriate charging method il-
lustration)
Do not quick charge a battery.

Never remove the MF battery sealing caps.

Do not use a high-rate battery charger
since it forces a high-amperage current
into the battery quickly and can cause bat-
tery overheating and battery plate damage.

If it is impossible to regulate the charging
current on the battery charger, be careful
not to overcharge the battery.

When charging a battery, be sure to remove
it from the motorcycle. (If charging has to
be done with the battery mounted on the
motorcycle, disconnect the negative bat-
tery lead from the battery terminal.)

To reduce the chance of sparks, do not
plug in the battery charger until the battery
charger leads are connected to the battery.

Before removing the battery charger lead
clips from the battery terminals, be sure to
turn off the battery charger.

Make sure the battery charger lead clips
are in full contact with the battery terminal
and that they are not shorted. A corroded
battery charger lead clip may generate heat
in the contact area and a weak clip spring
may cause sparks.

If the battery becomes hot to the touch at
any time during the charging process, dis-
connect the battery charger and let the bat-
tery cool before reconnecting it. Hot batter-
ies can explode!

As shown in the following illustration, the
open-circuit voltage of an MF battery stabi-
lizes about 30 minutes after charging has
been completed. Therefore, wait 30 min-
utes after charging is completed before
measuring the open-circuit voltage. 
						

							3-65
CHECKING AND CHARGING THE BATTERY
CHK
ADJ
Measure the open-circuit
voltage prior to charging.
Connect a charged and
AMP meter to the battery
and start charging.
Make sure that the current
is higher than the standard
charging current written on
the battery.
By turning the charging
voltage adjust dial, set the
charging voltage at 20 
 24 V.
Adjust the voltage so that the
current is at the standard
charging level.Monitor the amperage for
3 
 5 minutes to check if the
standard charging current is
reached.
Set the time according to the
charging time suitable for the
open-circuit voltage.
Refer to “Battery condition
checking steps”.If the current does not
exceed the standard
charging current after 5
minutes, replace the battery.
If charging requires more than 5 hours, it is advisable to check the
charging current after a lapse of 5 hours. If there is any change in the
amperage, readjust the voltage to obtain the standard charging
current.
Measure the battery open-circuit voltage after leaving the battery
unused for more than 30 minutes.
12.8 V or more --- Charging is complete.
12.7 V or less --- Recharging is required.
Under 12.0 V --- Replace the battery.YES NO
YES
NONOTE:
Voltage should be measured 30
minutes after the machine is stopped.
NOTE:
Set the charging voltage at 16 
 17 V.
(If the setting is lower, charging will be
insufficient. If too high, the battery will
be over-charged.)
Charging method using a variable-current (voltage) charger 
						

							3-66
CHECKING AND CHARGING THE BATTERY
CHK
ADJ
Measure the open-circuit
voltage prior to charging.
Connect a charger and
AMP meter to the battery
and start charging.
Make sure that the current
is higher than the standard
charging current written on
the battery.
Charge the battery until the battery’s
charging voltage is 15 V.This type of battery charger cannot
charge the MF battery. A variable
voltage charger is recommended.
Measure the battery open-circuit
voltage after leaving the battery
unused for more than 30 minutes.
12.8 V or more --- Charging is
complete.
12.7 V or less --- Recharging is
required.
Under 12.0 V --- Replace the battery.
Set the charging time at 20 hours
(maximum).
YES NO
NOTE:
Voltage should be measured 30
minutes after the machine is stopped.
NOTE:
Charging method using a constant voltage charger 
						

							3-67
CHECKING AND CHARGING THE BATTERY /
CHECKING THE FUSESCHK
ADJ
CAUTION:
CAUTION:
NOTE: 6. Install:

battery
7. Connect:

battery leads
(to the battery terminals)
First, connect the positive battery lead 
1,
and then the negative battery lead 
2.
8. Check:

battery terminals
Dirt 
 Clean with a wire brush.
Loose connection 
 Connect properly.
9. Lubricate:

battery terminals
Recommended lubricant
Dielectric grease
10. Install:

rider seat
Refer to “SEATS”.
EAS00181
CHECKING THE FUSES
The following procedure applies to all of the
fuses.
To avoid a short circuit, always set the main
switch to “OFF” when checking or replacing
a fuse.
1. Remove:

front cowling inner panel (left)
Refer to “COWLINGS”.

rider seat
Refer to “SEATS”.
2. Check:

fuse
a. Connect the pocket tester to the fuse and
check the continuity.
Set the pocket tester selector to “Ω  1”. 
						

							3-68
CHECKING THE FUSES
CHK
ADJ
WARNING
Pocket tester
90890-03112, YU-3112
b. If the pocket tester indicates “∞”, replace the
fuse.
3. Replace:

blown fuse
a. Set the main switch to “OFF”.
b. Install a new fuse of the correct amperage
rating.
c. Set on the switches to verify if the electrical
circuit is operational.
d. If the fuse immediately blows again, check
the electrical circuit.
Fuses
Amperage
ratingQ’ty
Main50 A1
Fuel injection
system15 A1
Headlight25 A1
Signaling
system10 A1
Ignition15 A1
Backup fuse
(odometer
and clock)
10 A1
Radiator
fan motor15 A2
Reserve25 A, 15 A,
10 A1
Never use a fuse with an amperage rating
other than that specified. Improvising or us-
ing a fuse with the wrong amperage rating
may cause extensive damage to the electri-
cal system, cause the lighting and ignition
systems to malfunction and could possibly
cause a fire.
4. Install:

front cowling inner panel (left)
Refer to “COWLINGS”.

rider seat
Refer to “SEATS”. 
						

							3-69
A
A
B
B
B
REPLACING THE HEADLIGHT BULBS
CHK
ADJ
WARNING
EAS00183
REPLACING THE HEADLIGHT BULBS
The following procedure applies to both of the
headlight bulbs.
1. Disconnect:

headlight bulb cover 
1

headlight coupler 2
Ahigh beam
Blow beam
2. Remove:

headlight bulb holder 
1
Ahigh beam
Blow beam
3. Remove:

headlight bulb
Since the headlight bulb gets extremely hot,
keep flammable products and your hands
away from the bulb until it has cooled down.
4. Install:

headlight bulb 
New
Secure the new headlight bulb with the head-
light bulb holder. 
						

							3-70
REPLACING THE HEADLIGHT BULBS /
ADJUSTING THE HEADLIGHT BEAMSCHK
ADJ
CAUTION:
a
b
a
b
Avoid touching the glass part of the head-
light bulb to keep it free from oil, otherwise
the transparency of the glass, the life of the
bulb and the luminous flux will be adversely
affected. If the headlight bulb gets soiled,
thoroughly clean it with a cloth moistened
with alcohol or lacquer thinner.
5. Install:

headlight bulb holder
6. Install:

headlight bulb cover (high beam)

headlight bulb coupler (low beam)
7. Connect:

headlight coupler (high beam)

headlight cover (low beam)
EAS00185
ADJUSTING THE HEADLIGHT BEAMS
The following procedure applies to both of the
headlights.
1. Remove:

front cowling inner panels
Refer to “COWLINGS”.
2. Adjust:

headlight beam (vertically)
a. Turn the adjusting screw 
1 in direction a or
b.
Direction
Headlight beam is raised.
DirectionHeadlight beam is 
lowered.
3. Adjust:

headlight beam (horizontally)
a. Turn the adjusting screw 
2 in direction a or
b.
Direction
Headlight beam moves to
the left.
DirectionHeadlight beam moves to
the right.
4. Install:

front cowling inner panels
Refer to “COWLINGS”. 
						

							4-1
4
FRONT WHEEL AND BRAKE DISCSCHAS
Order Job / Part Q’ty Remarks
1
2
3
4
5
6
7
8
9
10Removing the front wheel and brake
discs
Side reflector (left and right)
Brake hose holder (left and right)
Side reflector bracket
Front brake caliper (left and right)
Front wheel axle pinch bolt
Front wheel axle bolt
Front wheel axle
Collar (left and right)
Front wheel
Front brake disc (left and right)2
2
2
2
4
1
1
2
1
2Remove the parts in the order listed.
Place the motorcycle on a suitable stand
so that the front wheel is elevated.
For installation, reverse the removal 
procedure.
NOTE:
35 Nm (3.5 m
kg, 25 ft
lb)
6 Nm (0.6 m
kg, 4.3 ft
lb)
91 Nm (9.1 m
kg, 66 ft
lb)
20 Nm (2.0 m
kg, 13 ft
lb)
6 Nm (0.6 m
kg, 4.3 ft
lb)
18 Nm (1.8 m
kg, 13 ft
lb)
2 Nm (0.2 m
kg, 1.4 ft
lb)
2 Nm (0.2 m
kg, 1.4 ft
lb)
EAS00514
CHASSIS
FRONT WHEEL AND BRAKE DISCS 
						

							4-2
FRONT WHEEL AND BRAKE DISCSCHAS
Order Job / Part Q’ty Remarks
Disassembling the front wheel
Oil seal (left and right)
Wheel bearing (left and right)
Spacer2
2
1Disassemble the parts in the order listed.
For assembly, reverse the disassembly 
procedure.
1
2
3
EAS00518 
						

							4-3
FRONT WHEEL AND BRAKE DISCSCHAS
WARNING
NOTE:
NOTE:
NOTE:
WARNING
EAS00521
REMOVING THE FRONT WHEEL
1. Stand the motorcycle on a level surface.
Securely support the motorcycle so that
there is no danger of it falling over.
Place the motorcycle on a suitable stand so that
the front wheel is elevated.
2. Remove:

left brake caliper

right brake caliper
Refer to “FRONT BRAKE CALIPERS”.
Do not apply the brake lever when removing the
brake calipers.
3. Elevate:

front wheel
Place the motorcycle on a suitable stand so that
the front wheel is elevated.
4. Loosen :

front wheel axle pinch bolt
5. Remove :

front wheel axle bolt

front wheel axle

front wheel
EAS00525
CHECKING THE FRONT WHEEL
1. Check:

wheel axle
Roll the wheel axle on a flat surface.
Bends 
 Replace.
Do not attempt to straighten a bent wheel
axle.
2. Check:

tire

front wheel
Damage / wear 
 Replace.
Refer to “CHECKING THE TIRES” and
“CHECKING THE WHEELS” in chapter 3.