Yamaha R1 2004 ServiceManual
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2-13 CHASSIS SPECIFICATIONSSPEC ItemStandardLimit Front suspension Suspension type Front fork type Front fork travel Spring Free length Spacer length Installed length Spring rate (K1) Spring stroke (K1) Inner tube outer diameter Inner tube bending limit Optional spring available Fork oil Recommended oil Quantity (each front fork leg) Level (from the top of the outer tube, with the outer tube fully compressed, and without the fork spring) Spring preload adjusting positions Minimum Standard Maximum Rebound damping adjusting positions Minimum* Standard* Maximum* Compression damping adjusting positions Minimum* Standard* Maximum* *from the fully turned-in position Telescopic fork Coil spring / oil damper 120 mm (4.72 in) 236.5 mm (9.31 in) 100 mm (3.937 in) 222.5 mm (8.76 in) 8.83 N / mm (0.90 kg / mm, 50.42 lb / in) 0 120 mm (0 4.7244 in) 43 mm (1.69 in) No Suspension oil “01” 0.53 L (0.47 Imp qt, 0.56 US qt) 76 mm (2.99 in) 8 4.5 1 26 10 1 25 10 1 231.8 mm (9.13 in) 0.2 mm (0.01 in)
2-14 CHASSIS SPECIFICATIONSSPEC ItemStandardLimit Steering Steering bearing type Angular bearing Lock to lock angle (left) Lock to lock angle (right)27 27 Rear suspension Suspension type Rear shock absorber assembly type Rear shock absorber assembly travel Spring Free length Installed length Spring rate (K1) Spring stroke (K1) Optional spring available Standard spring preload gas / air pressure Spring preload adjusting positions Minimum Standard Maximum Rebound damping adjusting positions Minimum* Standard* Maximum* Compression damping adjusting positions Minimum* Standard* Maximum* *from the fully turned-in position Swingarm (link suspension) Coil spring / gas-oil damper 65 mm (2.56 in) 173.5 mm (6.83 in) 163.5 mm (6.44 in) 83.4 N / mm (8.50 kg / mm, 476.21 lb / in) 0 65 mm (0.00 2.56 in) No 1,200 kPa (12 kg / cm 2, 12 bar, 171 psi) 1 4 9 20 17 1 20 12 1 Swingarm Free play (at the end of the swingarm) Radial Axial 1.0 mm (0.04 in) 1.0 mm (0.04 in) Drive chain Model (manufacturer) Link quantity Drive chain slack Maximum ten-link section 50VA8 (DAIDO) 11 6 25 35 mm (0.98 1.38 in) 150.1 mm (5.91 in)
2-15 ELECTRICAL SPECIFICATIONSSPEC ELECTRICAL SPECIFICATIONS ItemStandardLimit System voltage12 V Ignition system Ignition system type Ignition timing Crankshaft position sensor resistance / color T.C.I. unit model (manufacturer) DC. T.C.I. 5 BTDC at 1,050 r / min 336 504 Ω at 20C (68F) / Gy-B F8T822 (MITSUBISHI) (USA) F8T823 (MITSUBISHI) (CAL) Ignition coils Model (manufacturer) Minimum ignition spark gap Primary coil resistance Secondary coil resistance F6T558 (MITSUBISHI) 6 mm (0.24 in) 1.19 1.61 Ω at 20C (68F) 8.5 11.5 kΩ at 20C (68F) Charging system System type Model (manufacturer) Normal output Stator coil resistance / color A.C. magneto F4T850 (MITSUBISHI) 14 V / 560 W at 5,000 r / min 0.14 0.18 Ω at 20C (68F) / W-W Rectifier / regulator Regulator type Model (manufacture) Semi conductor short circuit FH011AA (SHINDENGEN) () No-load regulated voltage Rectifier capacity Withstand voltage () 14.3 15.1 V 50 A 100 V Battery Battery type Battery voltage / capacity Specific gravity Manufacturer Ten hour rate amperage YTZ10S 12 V / 8.6 Ah 1.310 YUASA 0.8 A Headlight typeHalogen bulb Bulbs (voltage / wattage quantity) Headlight Auxiliary light Tail / brake light Front turn signal light / position light Rear turn signal light Licence plate light Meter light 12 V 55 W 4 12 V 5 W 2 LED 1 12 V 21 W / 5 W 2 12 V 21 W 2 12 V 5 W 1 LED 1
2-16 ELECTRICAL SPECIFICATIONSSPEC ItemStandardLimit Indicator light (voltage / wattage quantity) Neutral indicator light High beam indicator light Oil level warning light Turn signal indicator light Fuel level warning light Coolant temparture indicator light Engine trouble warning light Shift timing indicator light LED 1 LED 1 LED 1 LED 2 LED 1 LED 1 LED 1 LED 1 Electric starting system System type Starter motor Model (manufacturer) Power output Brushes Overall length Spring force Armature coil resistance Commutator diameter Mica undercut Constant mesh 5VY (YAMAHA) 0.9 kW 10.8 mm (0.43 in) 5.28 7.92 N (538 808 g, 18.99 28.48 oz) 0.0090 0.0110 Ω at 20C (68F) 24.5 mm (0.96 in) 1.5 mm (0.06 in) 3.6 mm (0.14 in) 23.5 mm (0.93 in) Starter relay Model (manufacturer) Amperage Coil resistance 2768079-A (JIDECO) 180 A 4.18 4.62 Ω at 20C (68F) Horn Horn type Model (manufacturer) quantity Max. amperage Performance Coil resistance Plane YF-12 (NIKKO) 1 3 A 105 113 db / 2 m 1.15 1.25 Ω at 20C (68F) Turn signal relay Relay type Model (manufacturer) Self-cancelling device built-in Turn signal blinking frequency Wattage Full transistor FE218BH (DENSO) No 75 95 cycles / min. 21 W 2 + 3.4 W Oil level switch Model (manufacturer) 5VY (SOMIC ISHIKAWA) EXUP servo motor Model (manufacturer) 5VY (YAMAHA)
2-17 ELECTRICAL SPECIFICATIONSSPEC ItemStandardLimit Fuses (amperage quantity) Main fuse Fuel injection system fuse Headlight fuse Signaling system fuse Ignition fuse Radiator fan motor fuse Backup fuse (odometer and clock) Reserve fuse 50 A 1 15 A 1 25 A 1 10 A 1 15 A 1 15 A 2 10 A 1 25 A, 15 A, 10 A 1
2-18 EAS00030 GENERAL TIGHTENING TORQUE SPECIFICATIONS This chart specifies tightening torques for stan- dard fasteners with a standard ISO thread pitch. Tightening torque specifications for spe- cial components or assemblies are provided for each chapter of this manual. To avoid war- page, tighten multi-fastener assemblies in a crisscross pattern and progressive stages until the specified tightening torque is reached. Un- less otherwise specified, tightening torque specifications require clean, dry threads. Com- ponents should be at room temperature. A: Distance between flats B: Outside thread diameter A (nut)B (bolt)General tightening torques 10 mm 12 mm 14 mm 17 mm 19 mm 22 mm6 mm 8 mm 10 mm 12 mm 14 mm 16 mmNm mkg 6 15 30 55 85 1300.6 1.5 3.0 5.5 8.5 13.0 ftlb 4.3 11 22 40 61 94 CONVERSION TABLE / GENERAL TIGHTENING TORQUE SPECIFICATIONS SPEC EAS00028 CONVERSION TABLE All specification data in this manual are listed in SI and METRIC UNITS. Use this table to convert METRIC unit data to IMPERIAL unit data. Ex. METRIC MULTIPLIER IMPERIAL ** mm 0.03937 = ** in 2 mm 0.03937 = 0.08 in CONVERSION TABLE METRIC TO IMPERIAL Metric unitMultiplierImperial unit Tighten- ing torquemkg mkg cmkg cmkg7.233 86.794 0.0723 0.8679ftlb inlb ftlb inlb Weightkg g2.205 0.03527lb oz Speedkm / hr0.6214mph Distance km m m cm mm0.6214 3.281 1.094 0.3937 0.03937mi ft yd in in Volume / Capacity cc (cm3) cc (cm3) lt (liter) lt (liter)0.03527 0.06102 0.8799 0.2199oz (IMP liq.) cuin qt (IMP liq.) gal (IMP liq.) Misc. kg / mm kg / cm2 Centigrade (C) 55.997 14.2234 9 / 5+32lb / in psi (lb / in2) Fahrenheit (F)
2-19 TIGHTENING TORQUESSPEC Use a lock washer TIGHTENING TORQUES ENGINE TIGHTENING TORQUES ItemFastenerThreadQ’tyTightening torqueRemarksItemFastenersizeQtyNmmkgftlbRemarks Spark plugs—M104131.39.4 Cylinder headNutM1010See NOTE 1 BoltM62121.28.7 Camshaft capsBoltM628101.07.2 Cylinder head coverBoltM66121.28.7 Cylinder head (exhaust pipe)Stud boltM88151.511 Air indication system capBoltM64101.07.2 Camshaft sprocketsBoltM74242.417 Cylinder head and throttle bodyClampM5430.32.2 Connecting rod capsBoltM8820+1502.0+15014+150 Generator rotorBoltM101606.043 Timing chain tensionerBoltM62101.07.2 Water pump outlet pipeBoltM61101.07.2 Water pump inlet pipeBoltM61101.07.2 (water pump side) Water pump inlet pipe (front side)BoltM61101.07.2 Oil / water pump assembly sprocketBoltM61151.511 Water pumpBoltM62121.28.7 Thermostat coverNutM62101.07.2 Thermostat inlet pipeBoltM61101.07.2 Oil coolerBoltM201636.346 Engine oil drain boltBoltM141434.331 Oil pipeBoltM62101.07.2 Oil strainerBoltM63101.07.2 Oil delivery pipeBoltM63101.07.2 Oil filter union boltBoltM201707.051 Oil filter—M201171.712 Oil panBoltM614121.28.7 Oil panBoltM61121.28.7 Air filter case coverScrewM5101.70.171.2 Throttle body and throttle body jointClampM5430.32.2 Throttle body and funnelBoltM564.20.423.0 Throttle cableNutM614.50.453.3 Throttle cable adjusterBoltM614.50.453.3 Stator coilScrewM63141.410 Generator rotor cover and bearing housingScrewM63101.07.2 Pull lever coverBoltM62101.07.2 Thermostat assembly stayBoltM62101.07.2 Starter clutch idler gearBoltM61101.07.2 Clutch bossNutM201959.569Stake Clutch springBoltM66101.07.2 Drive sprocketNutM221858.561
2-20 TIGHTENING TORQUESSPEC ItemFastenerThreadQ’tyTightening torqueRemarksItemFastenersizeQtyNmmkgftlbRemarks Exhaust pipe and cylinder headNutM88202.014 Catalyst pipe assembly and mufflerBoltM82202.014 Exhaust pipe and exhaust valveBoltM65101.07.2 pipe assembly Exhaust valve pipe and housingBoltM61101.07.2 Pulley and shaft armNutM6170.75.0 EXUP pulley bracketBoltM61101.07.2 EXUP pulley coverBoltM62101.07.2 Exhaust valve pipe and bracketBoltM81202.014 EXUP cable nutNutM6270.75.0 Catalyst pipe bracket and frameBoltM81202.014 Catalyst pipe and catalyst pipeBoltM81202.014 bracket Exhaust valve pipe and catalyst pipeBoltM81202.014 EXUP servo motorBoltM6270.75.0 Muffler and rear frameBoltM82232.317 Muffler coverBoltM62101.07.2 CrankcaseStud boltM101080.85.8 Crankcase (main journal)BoltM910See NOTE 2 CrankcaseBoltM610121.28.7 CrankcaseBoltM81242.417 CrankcaseBoltM85242.417 Generator rotor coverBoltM64121.28.7 Generator rotor coverBoltM83222.216 Drive sprocket coverBoltM62101.07.2 Drive sprocket coverBoltM61101.07.2 Crankcase cover (left)ScrewM63101.07.2 Clutch coverBoltM67121.28.7 Clutch coverBoltM61121.28.7 Pickup rotor coverBoltM66121.28.7 Breather coverBoltM64121.28.7 Breather plateBoltM63101.07.2 PlateBoltM62101.07.2 Pickup rotor cover blind boltBoltM81151.511 Generator rotor cover plugPlugM20180.85.8 Main gallery plug (oil return)PlugM16380.85.8 Main gallery plugPlugM20180.85.8 Oil return pipeBoltM62101.07.2 Oil return plugScrewM122242.417 Stator coil leadBoltM61101.07.2
2-21 TIGHTENING TORQUESSPEC NOTE 1: NOTE 2: ItemFastenerThreadQ’tyTightening torqueRemarksItemFastenersizeQtyNmmkgftlbRemarks Main axle bearing housingBoltM63121.28.7 Shift fork shaft stopperBoltM62101.07.2 Stopper screwScrewM81222.216 Shift rod lock nut (rear)NutM6170.75.0Left thread Shift rod lock nut (front)NutM6170.75.0 Shift rod jointBoltM61101.07.2 Shift armBoltM61101.07.2 E.C.U.ScrewM6270.75.0 Neutral switch—M101202.015 EXUP servo motor coverScrewM5220.21.5 Coolant temperature sensor—M121181.813 Cylinder identification sensorBoltM6180.85.7 Atmospheric pressure sensorScrewM5270.75.0 Crankshaft position sensorBoltM61101.07.2 Oil level switchBoltM62101.07.2 1. First, tighten the bolts to approximately 19 Nm (1.9 mkg, 14 ftlb) with a torque wrench following the tightening order. 2. Retighten the bolts 67 Nm (6.7 mkg, 48 ftlb) with a torque wrench. 1. First, tighten the bolts to approximately 20 Nm (2.0 mkg, 15 ftlb) with a torque wrench following the tightening order. 2. Loosen the all bolts one by one following the tightening order and then tighten them to 20 Nm (2.7 mkg, 15 ftlb) again. 3. Retighten the bolts further to reach the specified angle (60).
2-22 TIGHTENING TORQUESSPEC Cylinder head tightening sequence: Crankcase tightening sequence.