Yamaha R1 2004 ServiceManual
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1-5 FEATURES GEN INFO NOTE: NOTE: To set the shift timing indicator light activation function The shift timing indicator light activation function can be set between 7000 r/min and 15000 r/m. From 7000 r/min to 12000 r/min, the indicator light can be set in increments of 500 r/min. From 12000 r/min to 15000 r/min, the indicator light can be set in increments of 200 r/min. 1. Push the “RESET” button to select the desired engine speed for activating the indicator light. 2. Push the “SELECT” button to confirm the selected engine speed. The control mode changes to the shift timing indicator light deactivation function. To set the shift timing indicator light deactivation function The shift timing indicator light activation function can be set between 7000 r/min and 15000 r/min. From 7000 r/min to 12000 r/min, the indicator light can be set in increments of 500 r/min. From 12000 r/min to 15000 r/min, the indicator light can be set in increments of 200 r/min. Be sure to set the deactivation function to a higher engine speed than for the activation function, otherwise the shift timing indicator light will remain deactivated. 1. Push the “RESET” button to select the desired engine speed for deactivating the indicator light. 2. Push the “SELECT” button to confirm the selected engine speed. The control mode changes to the shift timing indicator light brightness function. To adjust the shift timing indicator light brightness 1. Push the “RESET” button to select the desired indicator light brightness level. 2. Push the “SELECT” button to confirm the selected indicator light brightness level. The right display will return to the odometer or tripmeter mode
1-6 springlip oil grease lip IMPORTANT INFORMATION GEN INFO EAS00020 IMPORTANT INFORMATION PREPARATION FOR REMOVAL AND DISASSEMBLY 1. Before removal and disassembly, eliminate all dirt, mud, dust and foreign material. 2. Use only the proper tools and cleaning equipment. Refer to the “SPECIAL TOOLS”. 3. When disassembling, always keep mated parts together. This includes gears, cylin- ders, pistons and other parts that have been “mated” through normal wear. Mated parts must always be reused or replaced as an as- sembly. 4. During disassembly, clean all of the parts and place them in trays in the order of disas- sembly. This will speed up assembly and al- low for the correct installation of all parts. 5. Keep all parts away from any source of fire. EAS00021 REPLACEMENT PARTS Use only genuine Yamaha parts for all replace- ments. Use oil and grease recommended by Yamaha for all lubrication jobs. Other brands may be similar in function and appearance, but inferior in quality. EAS00022 GASKETS, OIL SEALS AND O-RINGS 1. When overhauling the engine, replace all gaskets, seals and O-rings. All gasket sur- faces, oil seal lips and O-rings must be cleaned. 2. During reassembly, properly oil all mating parts and bearings and lubricate the oil seal lips with grease.
1-7 IMPORTANT INFORMATION GEN INFO CAUTION: EAS00023 LOCK WASHERS / PLATES AND COTTER PINS After removal, replace all lock washers / plates 1 and cotter pins. After the bolt or nut has been tightened to specification, bend the lock tabs along a flat of the bolt or nut. EAS00024 BEARINGS AND OIL SEALS Install bearings and oil seals so that the manufacturer’s marks or numbers are visible. When installing oil seals, lubricate the oil seal lips with a light coat of lithium-soap-based grease. Oil bearings liberally when installing, if appropriate. 1Oil seal Do not spin the bearing with compressed air because this will damage the bearing sur- faces. 1Bearing EAS00025 CIRCLIPS Before reassembly, check all circlips carefully and replace damaged or distorted circlips. Al- ways replace piston pin clips after one use. When installing a circlip 1, make sure the sharp-edged corner 2 is positioned opposite the thrust 3 that the circlip receives. 4Shaft
1-8 CHECKING THE CONNECTIONS GEN INFO NOTE: NOTE: NOTE: EAS00026 CHECKING THE CONNECTIONS Check the leads, couplers, and connectors for stains, rust, moisture, etc. 1. Disconnect: lead coupler connector 2. Check: lead coupler connector Moisture Dry with an air blower. Rust / stains Connect and disconnect sev- eral times. 3. Check: all connections Loose connection Connect properly. If the pin 1 on the terminal is flattened, bend it up. 4. Connect: lead coupler connector Make sure all connections are tight. 5. Check: continuity (with the pocket tester) Pocket tester 90890-03112, YU-3112 If there is no continuity, clean the terminals. When checking the wire harness, perform steps (1) to (3). As a quick remedy, use a contact revitalizer available at most part stores.
1-9 SPECIAL TOOLS GEN INFO NOTE: EAS00027 SPECIAL TOOLS The following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools as this will help prevent damage caused by the use of inappropriate tools or improvised techniques. Special tools, part numbers or both may differ depending on the country. When placing an order, refer to the list provided below to avoid any mistakes. For U.S.A. and Canada, use part number starting with “YM-”, “YU-”, or “ACC-”. For others, use part number starting with “90890-”. Tool No. Tool name / FunctionIllustration 90890-01304 YU-01304 Piston pin puller This tool is used to remove the piston pins. Radiator cap tester 90890-01325 YU-24460-01 Adapter 90890-01352 YU-33984Radiator cap tester Radiator cap tester adapter These tools are used to check the cooling system. 90890-01403 YU-33975 Steering nut wrench This tool is used to loosen or tighten the steering stem ring nuts. 90890-01423 YM-01423 Damper rod holder This tool is used to hold the damper rod as- sembly when loosening or tightening the damper rod assembly bolt. 90890-01426 YU-38411 Oil filter wrench This tool is needed to loosen or tighten the oil filter cartridge. 90890-01434 YM-01434 Rod holder This tool is used to support the damper ad- justing rod. Rod puller 90890-01437 YM-01437 Rod puller attachment 90890-01436 YM-01436Rod puller Rod puller attachment These tools are used to pull up the front fork damper rod.
1-10 SPECIAL TOOLS GEN INFO Tool No.Tool name / FunctionIllustration 90890-01441 YM-01441 Fork spring compressor This tool is used to disassemble or assemble the front fork legs. 90890-01442 YM-01442 Fork seal driver This tool is used to install the front fork’s oil seal and dust seal. 90890-03094 YU-08030 Vacuum gauge This guide is used to synchronize the car- buretors. Compression gauge 90890-03081 YU-33223 Adapter 90890-04136Compression gauge Compression gauge adapter These tools are used to measure engine compression. Valve spring compressor 90890-04019 YM-04019 Attachment 90890-04108 YM-01253 90890-04114 YM-4114Valve spring compressor Valve spring compressor attachment These tools are used to remove or install the valve assemblies. Middle driven shaft bearing driver 90890-04058 YM-4058 Mechanical seal installer 90890-04078 YM-33221Middle driven shaft bearing driver Mechanical seal installer These tools are used to install the water pump seal. 90890-04086 YM-91042 Clutch holding tool This tool is used to hold the clutch boss when removing or installing the clutch boss nut. 90890-04111 90890-04116 YM-4116 Valve guide remover This tool is used to remove or install the valve guides. 90890-04112 90890-04117 YM-4117 Valve guide installer This tool is used to install the valve guides.
1-11 SPECIAL TOOLS GEN INFO Tool No.Tool name / FunctionIllustration 90890-04113 YM-04113 90890-04118 YM-4118Valve guide reamer This tool is used to rebore the new valve guides. 90890-06754 YM-34487 Ignition checker This tool is used to check the ignition sys- tem components. 90890-85505 ACC-1109-0501 Yamaha bond No. 1215 This bond is used to seal two mating sur- faces (e.g., crankcase mating surfaces). 90890-03174 Digital circuit tester This tool is used to check the electrical sys- tem. Pivot shaft wrench 90890-01471 YM-01471 Pivot shaft wrench adapter 90890-01476Pivot shaft wrench Pivot shaft wrench adapter This tool is need to loosen or tighten the spacer bolt. 90890-03132 YU-3112 Pocket tester This instrument is needed for checking the engine oil temperature. Oil pressure gauge 90890-03153 YU-03153 Adapter 90890-03139Oil pressure gauge Adapter These tools are used to measure engine oil pressure. 90890-06756 Vacuum/pressure pump gauge set This tool used to measure the vacuum pres- sure. 90793-80009 Engine tachometer This tool is needed for observing engine rpm.
1-12 SPECIAL TOOLS GEN INFO Tool No.Tool name / FunctionIllustration 90890-04101 Valve lapper This tool is needed to remove and install the valve lifter. 90890-03176 YM-03176 Fuel pressure adapter This tool is needed to measure fuel pres- sure. 90890-03153 YU-03153 Pressure gauge This tool is used to measure fuel pressure. 90890-04143 YM-04143 Camshaft wrench This tool is used to hold and rotate the cam- shaft sprocket.
2-1 GENERAL SPECIFICATIONSSPEC SPECIFICATIONS GENERAL SPECIFICATIONS ItemStandardLimit Model code5VY4 (USA), 5VY5 (CAL) 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) Weight Wet (with oil and a full fuel tank) Maximum load (except motorcycle) 193 kg (425 lb) (USA) 194 kg (428 lb) (CAL) 202 kg (445 lb) (USA) 201 kg (443 lb) (CAL)
2-2 ENGINE SPECIFICATIONSSPEC 2 ENGINE SPECIFICATIONS ItemStandardLimit 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 1,250 r / min 22 kPa (165 mmHg, 6.5 inHg) 1,480 kPa (14.80 kg / cm 2,14.80 bar, 210.5 psi) at 350 r / min 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) 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 At 5C (40F) or higher Yamalube 4 (20W40) or SAE 20W40 type SE motor oil At 15C (60F) or lower Yamalube 4 (10W30) or SAE 10W30 type SE motor oil 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 / cm 2 at 5,000 r / min) (2.3 bar at 5,000 r / min) (32.7 psi at 5,000 r / min) 100C (212F) 600 680 kPa (6.0 6.8 kg / cm 2, 6.0 6.8 bar, 87.0 98.6 psi)