Yamaha R1 2004 ServiceManual
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2-43 33Throttle body side cap 34Mud guard 35Turn signal light lead 36License plate light lead 37Rear fender rib 38Speed sensor lead 39Rear brake light switch lead 40Rear frame 41Swingarm bracket 42Main fuse lead 43Starting circuit cut-off relay lead 44Turn signal light relay lead 45Starter relay lead 46Main fuse lead (To the battery positive lead) 47Right handlebar switch lead 17Battery negative lead 18Starter motor lead 19A.C.magneto lead 20Oil level switch lead 21Sidestand switch lead 22Throttle body lead 23Coolant reservoir tank drain hose 24Fuel tank drain hose 25Cover 7 26Radiator fan motor lead (left) 27Radiator fan motor lead (right) 28Wire harness 29Pipe 3 30Frame 31Coolant reservoir tank hose 32Thermo stat assembly breather hose CABLE ROUTINGSPEC 1Heat protector 2Crankshaft position sensor lead 3Neutral switch lead 4Ground lead 5Coolant reservoir tank 6Battery positive lead 7Starter relay 8Turn signal relay 9Main fuse 10Lean angle cut-off switch 11Atmospheric pressure sensor 12Tail / brake light lead 13Rear fender 14Seat lock cable 15Anti safety alarm coupler 16Starting circuit cut-off relay
2-44 K Pass the water hose lower side of the thermostat, and between the ground lead and the neutral switch. L Install the leads so that the en- gine ground lead is positioned lower and the battery negative lead to be upper. Install the pro- trusion of each lead to be above the vehicle. M Route the crankshaft position sensor lead under the wire har- ness. N To the fuel pump O Clamp the wire harness winding in and insert it to the frame hole.A Pass the wire harness through the clamp inserted to the radiator stay. B To the headlight lead C Clamp the lead between three protrusions of the pipe (the first and second parts from the ve- hicle front). Point the tip of the clamp (excessive part) to the in- side of the vehicle. D To the vehicle right side diagram E To the engine F Clamp the lead between three protrusions of the pipe (the in- side and outside of the vehicle).G Point the tip of the clamp (exces- sive part) to the inside of the ve- hicle. H All hoses and leads should be routed over the vehicle’s upper side above the heat protector. I To the starter motor J Fasten the wire harness, clank shaft position sensor lead, rear brake light switch lead and speed sensor lead with a clamp. Then, point the tip of the clamp (cut the tip of the clamp leaving 2 to 4 mm (0.08 to 0.16 in).) to the inside of the vehicle. CABLE ROUTINGSPEC
2-45 W Point the tip of the clamp (sur- plus section) to the rear side of the vehicle. Fasten the starter relay lead, turn signal relay lead, main fuse lead, main fuse lead (from the battery positive lead) and starting circuit cut-off relay lead with a clamp. X Route each lead under the wire harness. Y Fasten the wire harness, battery negative lead and starter motor lead with a clamp. Point the tip of the clamp (excessive part) to the inside of the vehicle.P Pass the lead through inside of the battery band. Q Press on the tip of the clamp af- ter passing the leads through it. R Insert the tail / brake light lead to the rear frame hole. S Insert the clamp from the vehicle front to the rear side and fasten each lead, coupler and onion- head to the fender rib, and then point the tip of the clamp (exces- sive part) to the upper side of the vehicle. T Hold down the clamp tips after passing each lead.U Make sure to position the cou- pler at the downmost position of leads. However, the coupler should be set in the rear frame so that it is not caught by the seat bottom, cover and other compo- nents. V Point the tip of the clamp (exces- sive part) to the inside of the ve- hicle. Fasten the wire harness with a clamp. CABLE ROUTINGSPEC
2-46 DD Fasten the wire harness, A.C.magneto lead, and throttle body lead with a clamp. Point the tip of the clamp (cut the tip of the clamp leaving 2 to 4 mm (0.08 to 0.16 in).) to the inside of the ve- hicle. EE To the air filter FF To the throttle body GG To install the cover 7, install so as to set each coupler in the cover. Make sure that each lead is not caught by the cover 7.Z Point the tip of the clamp (exces- sive part) to the down side of the vehicle. Fasten the wire har- ness, battery negative lead, A.C. magneto lead and starter motor lead with a clamp. AA To the speed sensor BB Insert the wire harness wrap- ping clamp to the hole of the frame. CC After passing the lead be- tween the wire harness and starter motor leads, fastening by the clamp should be can- celled and route the lead un- der the idle remote controller. CABLE ROUTINGSPEC HH Insert the wire harness wrap- ping clamp to the hole of the frame. II Make sure that the lead is fas- tened with the guide of the ra- diator stay. JJ To the right handlebar switch KK Do not place it beyond pipe 3 in the direction to the external part of the vehicle. LL Battery negative lead should not run on the swingarm bracket.
2-47 PP Route the leads in random or- der.MM Route each lead lower than the frame plate. Leads should be routed in random order. Clamp can be inserted in any direction. NN Route each lead higher than the frame plate, pass it to the inside of the vehicle from the hole. Leads should be routed in random order. Clamp can be inserted in any direction. OO The hoses should not be lo- cated higher than the throttle body side cap over the up side of the vehicle. CABLE ROUTINGSPEC
2-48 a Fuel piping connector attach- ment directions. (fuel pump side) 1. Insert the connector until the click sound is heard and check that the connector does not come off. Make sure that no for- eign matter is caught in the seal- ing section. (It is prohibited to wear the cotton work gloves or equivalent coverings.) G This part works as a dropout stopper. 2. After Item 1 mentioned above is finished, check that the clamp is inserted from the down side, and , and -sections are per- fectly equipped. ABC A Install the lip of O-ring facing up- ward. B Install the part pointing the white paint part of the hose to the left side of the vehicle. C Any direction of the clip grip can be accepted. D Install the clip grip as specified in the drawing. E Install the part pointing the white paint part of the hose to the left side of the vehicle. F Point the clip grip to the left side of the vehicle. CABLE ROUTINGSPEC 1Fuel tank 2O-ring 3Fuel tank drain hose 4Fuel tank breather hose 5Clip 6Air filter stay 7Fuel hose 2 83 way connector 9Pipe 10Fuel tank bracket 11Fuel hose clamp 12Fuel hose 1 13Fuel pump assembly
2-49 F Point the clip grip to the upper side of the vehicle. G Install the part pointing the yel- low paint mark to the front side of the vehicle. H Install the part pointing the yel- low paint mark to the left side of the vehicle.A Point the clip grip to the down side of the vehicle. B Insert the hose so that its tip of the nipple does not protrude. C Install the part pointing the white paint mark to the left side of the vehicle. D Insert the hose until it reaches the R-bottom of the pipe. E To the throttle body CABLE ROUTINGSPEC for CAL 1Clip 2Clamp 3Rivet 4Roll over valve assembly 5Balance pipe 6Pipe 4 7Canister hose 8Canister assembly 9Canister bracket 10Frame 11Canister stay 12Pipe 2 13Pipe 3
3-1 3 INTRODUCTION / PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM / GENERAL MAINTENANCE AND LUBRICATION CHARTCHK ADJ EAS00036 PERIODIC CHECKS AND ADJUSTMENTS INTRODUCTION This chapter includes all information necessary to perform recommended checks and adjustments. If followed, these preventive maintenance procedures will ensure more reliable vehicle operation, a longer service life and reduce the need for costly overhaul work. This information applies to vehicles already in service as well as to new vehicles that are being prepared for sale, All service technicians should be familiar with this entire chapter. PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM INITIALODOMETER READINGS No.ITEMROUTINE600 mi (1000 km) or 1 month4000 mi (7000 km) or 6 months8000 mi (13000 km) or 12 months12000 mi (19000 km) or 18 months16000 mi (25000 km) or 24 months20000 mi (31000 km) or 30 months 1*Fuel line (See page 3-33)Check fuel hoses for cracks or damage. Replace if necessary. 2*Spark plugs (See page 3-23)Check Condition. Adjust gap and clean. Replace every 8000 mi (13000 km) or 12 months.Replace.Replace. 3*Valve clearance (See page 3-11)Check and adjust valve clearance when en- gine is cold.Every 26600 mi (42000 km) 4*Crankcase breather system (See page 3-34)Check breather hose for cracks or damage. Replace if necessary. 5*Electronic fuel injection (See page 3-17, 21)Check and adjust engine idle speed and syn- chronization. 6*Exhaust system (See page 3-35)Check for leakage. Tighten if necessary. Replace gasket(s) if necessary. 7*Evaporative emission control system (For California only)Check control system for damage. Replace if necessary. 8*Air induction system (See page 7-46)Check the air cut-off valve, reed valve, and hose for damage. Replace any damaged parts if necessary. GENERAL MAINTENANCE AND LUBRICATION CHART INITIALODOMETER READINGS No.ITEMROUTINE600 mi (1000 km) or 1 month4000 mi (7000 km) or 6 months8000 mi (13000 km) or 12 months12000 mi (19000 km) or 18 months16000 mi (25000 km) or 24 months20000 mi (31000 km) or 30 months 1*Air filter element (See page 3-32)Check condition and damage.Replace if necessary. 2*Clutch (See page 3-31)Check operation.Adjust or replace cable. 3*Front brake (See page 3-42, 44, 45)Check operation, fluid level, and for fluid leak- age. Replace brake pads if necessary. 4*Rear brake (See page 3-43, 44, 45)Check operation, fluid level, and for fluid leak- age. Replace brake pads if necessary. 5*Brake hosesCheck for cracks or damage.5*Brake hoses(See page 3-46)Replace.Every 4 years 6*Wheels (See page 4-3)Check runout and for damage.Replace if necessary. 7*Tires (See page 3-58)Check tread depth and for damage.Replace if necessary.Check air pressure.Correct if necessary. 8*Wheel bearings (See page 4-3)Check bearings for smooth operation.Replace if necessary.
3-2 NOTE: GENERAL MAINTENANCE AND LUBRICATION CHART CHK ADJ NOTE: INITIALODOMETER READINGS No.ITEMROUTINE600 mi (1000 km) or 1 month4000 mi (7000 km) or 6 months8000 mi (13000 km) or 12 months12000 mi (19000 km) or 18 months16000 mi (25000 km) or 24 months20000 mi (31000 km) or 30 months 9*Swingarm pivot bearings (See page 4-71)Check bearing assemblies for looseness.Moderately repack with lithium-soap-based grease.Repack. 10Drive chain (See page 3-49, 50)Check chain slack/alignment and condition.Adjust and lubricate chain with a special O- ring chain lubricant thoroughly.Every 600 mi (800 km) and after washing the motorcycle or riding in the rain 11*Steering bearings (See page 3-51)Check bearing assembly for looseness.Moderately repack with lithium-soap-based grease every 16000 mi (25000 km) or 24 months.Repack. 12*Steering damper (See page 4-60)Check operation and for oil leakage. 13*Chassis fasteners (See page 2-23)Check all chassis fitting and fasteners.Correct if necessary. 14Brake and clutch lever pivot shafts (See page 3-61)Apply lithium-soap-based grease (all-purpose grease) lightly. 15Sidestand pivot(See page 3-61) Check operation. Apply lithium-soap-based grease (all-pur- pose grease) lightly. 16*Sidestand switch (See page 3-61, 8-4)Check operation and replace if necessary. 17*Front fork (See page 3-53)Check operation and for oil leakage.Replace if necessary. 18*Shock absorber assembly (See page 3-56, 4-67)Check operation and for oil leakage.Replace if necessary. 19*Rear suspension link pivots (See page 4-71)Check operation.Correct if necessary. 20Engine oil (See page 3-26, 28)Change (warm engine before draining.) 21*Engine oil filter cartridge (See page 3-28)Replace. 22*Cooling system Check hoses for cracks or damage.Replace if necessary. 22*Cooling system(See page 3-37, 38, 39)Change with ethylene glycol antifreeze cool- ant every 24 months.Change. 23*EXUP system (See page 3-36)Check operation, cable free play and pulley position.Every 12000 mi (19000 km) 24*Control cables (See page 3-61)Apply Yamaha chain and cable lube or en- gine oil SAE 10W-30 thoroughly. 25*Throttle grip housing and cable (See page 3-22)Check operation and free play.Adjust the throttle cable free play if necessary.Lubricate the throttle grip housing and cable. * Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service. From 24000 mi (37000 km) or 36 months, repeat the maintenance intervals starting from 8000 mi (13000 km) or 12 months. Air filter This model’s air filter is equipped with a disposable oil-coated paper element, which must not be cleaned with compressed air to avoid damaging it. The air filter element needs to be replaced more frequently when riding in unusually wet or dusty areas. Hydraulic brake service After disassembling the brake master cylinders and calipers, always change the fluid. Regularly check the brake fluid levels and fill the reservoirs as required. Every two years replace the internal components of the brake master cylinders and calipers, and change the brake fluid. Replace the brake hoses every four years and if cracked or damaged.
3-3 Order Job / Part Q’ty Remarks 1 2Removing the seats Rider seat Passenger seat1 1Remove the parts in the order listed. For installation, reverse the removal procedure. 7 Nm (0.7 mkg, 5.1 ftlb) SEATS CHK ADJ EAS00039 SEATS