2004 Yamaha YZF R1 Service Repair Manual

EAS00010 YZF-R1S/YZF-R1SC SERVICE MANUAL 2003 by Yamaha Motor Corporation, U.S.A. First edition, December 2003 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Corporation, U.S.A. is expressly prohibited. Printed in U.S.A. P/N LIT-11616-17-55

NOTE: WARNING CAUTION: EAS00030 NOTICE This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles should have a basic understanding of mechanics and the techniques to repair these types of vehicles. Repair and maintenance work attempted by anyone without this knowledge is likely to render the vehicle unsafe and unfit for use. This model has been designed and manufactured to perform within certain specifications in regard to performance and emissions. Proper service with the correct tools is necessary to ensure that the vehicle will operate as designed. If there is any question about a service procedure, it is imperative that you contact a Yamaha dealer for any service information changes that apply to this model. This policy is intended to provide the customer with the most satisfaction from his vehicle and to conform to federal environmental quality objectives. Yamaha Motor Company, Ltd. is continually striving to improve all of its models. Modifications and sig- nificant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will appear in future editions of this manual where applicable. S This Service Manual contains information regarding periodic maintenance to the emission control system. Please read this material carefully. S Designs and specifications are subject to change without notice. EAS00040 IMPORTANT MANUAL INFORMATION Particularly important information is distinguished in this manual by the following. The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! Failure to follow WARNING instructions could result in severe injury or death to the motorcycle operator, a bystander or a person checking or repairing the motorcycle. A CAUTION indicates special precautions that must be taken to avoid damage to the motorcycle. NOTE: A NOTE provides key information to make procedures easier or clearer.

1 2 4 8 3 5 6 7 EAS00007 HOW TO USE THIS MANUAL This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid out with the individual steps in sequential order. 1 The manual is divided into chapters. An abbreviation and symbol in the upper right corner of each page indicate the current chapter. Refer to “SYMBOLS”. 2 Each chapter is divided into sections. The current section title is shown at the top of each page, except in Chapter 3 (“PERIODIC CHECKS AND ADJUSTMENTS”), where the sub-section title(s) ap- pears. 3 Sub-section titles appear in smaller print than the section title. 4 To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each removal and disassembly section. 5 Numbers are given in the order of the jobs in the exploded diagram. A circled number indicates a disassembly step. 6 Symbols indicate parts to be lubricated or replaced. Refer to “SYMBOLS”. 7 A job instruction chart accompanies the exploded diagram, providing the order of jobs, names of parts, notes in jobs, etc. 8 Jobs requiring more information (such as special tools and technical data) are described sequen- tially.

22 1 3 5 7 9 2 4 8 6 24 25 23 21 19 20 18 16 17 15 14 13 11 12 10 GEN INFO SPEC ENG FI ELEC COOL CHK ADJ TRBL SHTG CHAS EAS00008 SYMBOLS The following symbols are not relevant to every vehicle. Symbols 1 to 9 indicate the subject of each chapter. 1 General information 2 Specifications 3 Periodic checks and adjustments 4 Chassis 5 Engine 6 Cooling system 7 Fuel injection system 8 Electrical system 9 Troubleshooting Symbols 10 to 17 indicate the following. 10 Serviceable with engine mounted 11 Filling fluid 12 Lubricant 13 Special tool 14 Tightening torque 15 Wear limit, clearance 16 Engine speed 17 Electrical data Symbols 18 to 23 in the exploded diagrams indicate the types of lubricants and lubrication points. 18 Engine oil 19 Gear oil 20 Molybdenum-disulfide oil 21 Wheel-bearing grease 22 Lithium-soap- based grease 23 Molybdenum-disulfide grease Symbols 24 to 25 in the exploded diagrams indicate the following. 24 Apply locking agent (LOCTITE  ) 25 Replace the part

GENERAL INFORMATION SPECIFICATIONS PERIODIC CHECKS AND ADJUSTMENTS CHASSIS ENGINE COOLING SYSTEM FUEL INJECTION SYSTEM ELECTRICAL SYSTEM TROUBLESHOOTING GEN INFO 1 SPEC 2 3 ENG 4 COOL 5 FI 6 CHAS 7 ELEC 8 TRBL SHTG 9 CHK ADJ EAS00012 TABLE OF CONTENTS

CHAPTER 1 GENERAL INFORMATION MOTORCYCLE IDENTIFICATION 1-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VEHICLE IDENTIFICATION NUMBER 1-1 . . . . . . . . . . . . . . . . . . . . . . . . MODEL LABEL 1-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FEATURES 1-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTRUMENT FUNCTIONS 1-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IMPORTANT INFORMATION 1-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PREPARATION FOR REMOVAL AND DISASSEMBLY 1-6 . . . . . . . . . REPLACEMENT PARTS 1-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GASKETS, OIL SEALS AND O-RINGS 1-6 . . . . . . . . . . . . . . . . . . . . . . . LOCK WASHERS /PLATES AND COTTER PINS 1-7 . . . . . . . . . . . . . . BEARINGS AND OIL SEALS 1-7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CIRCLIPS 1-7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE CONNECTIONS 1-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPECIAL TOOLS 1-9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHAPTER 2 SPECIFICATIONS GENERAL SPECIFICATIONS 2-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE SPECIFICATIONS 2-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHASSIS SPECIFICATIONS 2-11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ELECTRICAL SPECIFICATIONS 2-15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CONVERSION TABLE 2-18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GENERAL TIGHTENING TORQUE SPECIFICATIONS 2-18 . . . . . . . . . . . . TIGHTENING TORQUES 2-19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE TIGHTENING TORQUES 2-19 . . . . . . . . . . . . . . . . . . . . . . . . . . . CHASSIS TIGHTENING TORQUES 2-23 . . . . . . . . . . . . . . . . . . . . . . . . . . LUBRICATION POINTS AND LUBRICANT TYPES 2-25 . . . . . . . . . . . . . . . ENGINE 2-25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHASSIS 2-26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . COOLING SYSTEM DIAGRAMS 2-27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE OIL LUBRICATION CHART 2-29 . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LUBRICATION DIAGRAMS 2-30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CABLE ROUTING 2-35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHAPTER 3 PERIODIC CHECKS AND ADJUSTMENTS INTRODUCTION 3-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM 3-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GENERAL MAINTENANCE AND LUBRICATION CHART 3-1 . . . . . . . . . SEATS 3-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FUEL TANK 3-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE FUEL TANK 3-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE FUEL PUMP 3-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE FUEL PUMP 3-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE FUEL TANK 3-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . COWLINGS 3-7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FRONT COWLING AND SIDE COWLINGS 3-7 . . . . . . . . . . . . . . . . . . . REAR COWLING 3-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVAL 3-9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION 3-9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AIR FILTER CASE 3-10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE 3-11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ADJUSTING THE VALVE CLEARANCE 3-11 . . . . . . . . . . . . . . . . . . . . . . SYNCHRONIZING THE THROTTLE BODIES 3-17 . . . . . . . . . . . . . . . . . ADJUSTING THE EXHAUST GAS VOLUME 3-19 . . . . . . . . . . . . . . . . . . ADJUSTING THE ENGINE IDLING SPEED 3-21 . . . . . . . . . . . . . . . . . . . ADJUSTING THE THROTTLE CABLE FREE PLAY 3-22 . . . . . . . . . . . . CHECKING THE SPARK PLUGS 3-23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . MEASURING THE COMPRESSION PRESSURE 3-24 . . . . . . . . . . . . . . CHECKING THE ENGINE OIL LEVEL 3-26 . . . . . . . . . . . . . . . . . . . . . . . . CHANGING THE ENGINE OIL 3-28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MEASURING THE ENGINE OIL PRESSURE 3-29 . . . . . . . . . . . . . . . . . ADJUSTING THE CLUTCH CABLE FREE PLAY 3-31 . . . . . . . . . . . . . . . REPLACING THE AIR FILTER ELEMENT 3-32 . . . . . . . . . . . . . . . . . . . . CHECKING THE FUEL AND BREATHER HOSES 3-33 . . . . . . . . . . . . . CHECKING THE CRANKCASE BREATHER HOSE 3-34 . . . . . . . . . . . . CHECKING THE EXHAUST SYSTEM 3-35 . . . . . . . . . . . . . . . . . . . . . . . . ADJUSTING THE EXUP CABLES 3-36 . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE COOLANT LEVEL 3-37 . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE COOLING SYSTEM 3-38 . . . . . . . . . . . . . . . . . . . . . . . . CHANGING THE COOLANT 3-39 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHASSIS 3-42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ADJUSTING THE FRONT BRAKE 3-42 . . . . . . . . . . . . . . . . . . . . . . . . . . . ADJUSTING THE REAR BRAKE 3-43 . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE BRAKE FLUID LEVEL 3-44 . . . . . . . . . . . . . . . . . . . . . . ADJUSTING THE REAR BRAKE LIGHT SWITCH 3-45 . . . . . . . . . . . . . CHECKING THE FRONT AND REAR BRAKE PADS 3-45 . . . . . . . . . . . CHECKING THE FRONT AND REAR BRAKE HOSES 3-46 . . . . . . . . . BLEEDING THE HYDRAULIC BRAKE SYSTEM 3-47 . . . . . . . . . . . . . . . ADJUSTING THE SHIFT PEDAL 3-48 . . . . . . . . . . . . . . . . . . . . . . . . . . . . ADJUSTING THE DRIVE CHAIN SLACK 3-49 . . . . . . . . . . . . . . . . . . . . . LUBRICATING THE DRIVE CHAIN 3-50 . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING AND ADJUSTING THE STEERING HEAD 3-51 . . . . . . . . . CHECKING THE FRONT FORK 3-53 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ADJUSTING THE FRONT FORK LEGS 3-54 . . . . . . . . . . . . . . . . . . . . . . ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY 3-56 . . . . . CHECKING THE TIRES 3-58 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE WHEELS 3-60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING AND LUBRICATING THE CABLES 3-61 . . . . . . . . . . . . . . . LUBRICATING THE LEVERS AND PEDALS 3-61 . . . . . . . . . . . . . . . . . . LUBRICATING THE SIDESTAND 3-61 . . . . . . . . . . . . . . . . . . . . . . . . . . . . LUBRICATING THE REAR SUSPENSION 3-61 . . . . . . . . . . . . . . . . . . . . ELECTRICAL SYSTEM 3-62 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING AND CHARGING THE BATTERY 3-62 . . . . . . . . . . . . . . . . . CHECKING THE FUSES 3-67 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REPLACING THE HEADLIGHT BULBS 3-69 . . . . . . . . . . . . . . . . . . . . . . ADJUSTING THE HEADLIGHT BEAMS 3-70 . . . . . . . . . . . . . . . . . . . . . . CHAPTER 4 CHASSIS FRONT WHEEL AND BRAKE DISCS 4-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE FRONT WHEEL 4-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE FRONT WHEEL 4-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE BRAKE DISCS 4-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE FRONT WHEEL 4-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . ADJUSTING THE FRONT WHEEL STATIC BALANCE 4-7 . . . . . . . . . REAR WHEEL AND BRAKE DISC 4-9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REAR WHEEL 4-9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REAR BRAKE DISC AND REAR WHEEL SPROCKET 4-10 . . . . . . . . . REMOVING THE REAR WHEEL 4-12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE REAR WHEEL 4-13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE REAR WHEEL DRIVE HUB 4-13 . . . . . . . . . . . . . . . . . CHECKING AND REPLACING THE REAR WHEEL SPROCKET 4-13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE REAR WHEEL 4-14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . ADJUSTING THE REAR WHEEL STATIC BALANCE 4-14 . . . . . . . . . . .

FRONT AND REAR BRAKES 4-15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FRONT BRAKE PADS 4-15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REAR BRAKE PADS 4-16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REPLACING THE FRONT BRAKE PADS 4-18 . . . . . . . . . . . . . . . . . . . . . REPLACING THE REAR BRAKE PADS 4-20 . . . . . . . . . . . . . . . . . . . . . . FRONT BRAKE MASTER CYLINDER 4-22 . . . . . . . . . . . . . . . . . . . . . . . . REAR BRAKE MASTER CYLINDER 4-25 . . . . . . . . . . . . . . . . . . . . . . . . . DISASSEMBLING THE FRONT BRAKE MASTER CYLINDER 4-27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DISASSEMBLING THE REAR BRAKE MASTER CYLINDER 4-27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE FRONT AND REAR BRAKE MASTER CYLINDERS 4-28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ASSEMBLING AND INSTALLING THE FRONT BRAKE MASTER CYLINDER 4-29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ASSEMBLING THE REAR BRAKE MASTER CYLINDER 4-31 . . . . . . . FRONT BRAKE CALIPERS 4-33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REAR BRAKE CALIPER 4-35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DISASSEMBLING THE FRONT BRAKE CALIPERS 4-37 . . . . . . . . . . . DISASSEMBLING THE REAR BRAKE CALIPER 4-38 . . . . . . . . . . . . . . CHECKING THE FRONT AND REAR BRAKE CALIPERS 4-39 . . . . . . ASSEMBLING AND INSTALLING THE FRONT BRAKE CALIPERS 4-40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ASSEMBLING AND INSTALLING THE REAR BRAKE CALIPER 4-42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FRONT FORK 4-44 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FRONT FORK LEGS 4-44 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE FRONT FORK LEGS 4-47 . . . . . . . . . . . . . . . . . . . . . . . DISASSEMBLING THE FRONT FORK LEGS 4-48 . . . . . . . . . . . . . . . . . CHECKING THE FRONT FORK LEGS 4-49 . . . . . . . . . . . . . . . . . . . . . . . ASSEMBLING THE FRONT FORK LEGS 4-50 . . . . . . . . . . . . . . . . . . . . . INSTALLING THE FRONT FORK LEGS 4-55 . . . . . . . . . . . . . . . . . . . . . . HANDLEBARS 4-56 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE HANDLEBARS 4-58 . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE HANDLEBARS 4-58 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE HANDLEBARS 4-58 . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE STEERING DAMPER 4-60 . . . . . . . . . . . . . . . . . . . . . . . STEERING HEAD 4-61 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . UNDER BRACKET 4-61 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE UNDER BRACKET 4-63 . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE STEERING HEAD 4-63 . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE STEERING HEAD 4-64 . . . . . . . . . . . . . . . . . . . . . . . . .

2004 Yamaha YZF R1 Service Repair Manual

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