air filter YAMAHA YZF-R1 2004 Owners Manual
[x] Cancel search | Manufacturer: YAMAHA, Model Year: 2004, Model line: YZF-R1, Model: YAMAHA YZF-R1 2004Pages: 104, PDF Size: 5.19 MB
Page 6 of 104
TABLE OF CONTENTSSAFETY INFORMATION ..................1-1
DESCRIPTION ..................................2-1
Left view ..........................................2-1
Right view ........................................2-2
Controls and instruments.................2-3
INSTRUMENT AND CONTROL
FUNCTIONS.......................................3-1
Immobilizer system .........................3-1
Main switch/steering lock ................3-2
Indicator and warning lights ............3-3
Multi-function meter unit .................3-8
Anti-theft alarm (optional) .............3-13
Handlebar switches ......................3-13
Clutch lever ...................................3-15
Shift pedal .....................................3-15
Brake lever ...................................3-15
Brake pedal ..................................3-16
Fuel tank cap ................................3-16
Fuel ...............................................3-17
Fuel tank breather/overflow
hose ..........................................3-18
Catalytic converter ........................3-18
Seats ............................................3-19
Helmet holders .............................3-20
Adjusting the front fork ..................3-20
Adjusting the shock absorber
assembly ...................................3-22
Luggage strap holders ..................3-24
EXUP system ...............................3-25Sidestand ..................................... 3-25
Ignition circuit cut-off system ........ 3-26
PRE-OPERATION CHECKS............. 4-1
Pre-operation check list .................. 4-2
OPERATION AND IMPORTANT
RIDING POINTS................................. 5-1
Starting the engine ......................... 5-1
Shifting ........................................... 5-2
Tips for reducing fuel
consumption ............................... 5-3
Engine break-in .............................. 5-3
Parking ........................................... 5-4
PERIODIC MAINTENANCE AND
MINOR REPAIR................................. 6-1
Owner’s tool kit ............................... 6-1
Periodic maintenance and
lubrication chart .......................... 6-2
Removing and installing the cowling
and panels .................................. 6-6
Checking the spark plugs ............... 6-8
Engine oil and oil filter cartridge ..... 6-9
Coolant ......................................... 6-12
Replacing the air filter element ..... 6-14
Adjusting the engine idling
speed ........................................ 6-16
Adjusting the throttle cable free
play ........................................... 6-16
Adjusting the valve clearance ...... 6-17Tires ............................................. 6-17
Cast wheels ................................. 6-20
Adjusting the clutch lever free
play ........................................... 6-20
Adjusting the rear brake light
switch ....................................... 6-21
Checking the front and rear brake
pads .......................................... 6-21
Checking the brake fluid level ...... 6-22
Changing the brake fluid .............. 6-23
Drive chain slack .......................... 6-23
Lubricating the drive chain ........... 6-24
Checking and lubricating the
cables ....................................... 6-25
Checking and lubricating the
throttle grip and cable ............... 6-25
Checking and lubricating the
brake and clutch levers ............ 6-26
Checking and lubricating the
sidestand .................................. 6-26
Lubricating the swingarm
pivots ........................................ 6-27
Checking the front fork ................. 6-27
Checking the steering .................. 6-28
Checking the wheel bearings ....... 6-28
Battery ......................................... 6-29
Replacing the fuses ..................... 6-30
Replacing a headlight bulb .......... 6-32
Tail/brake light ............................. 6-35
Replacing a turn signal light
bulb ........................................... 6-35U5VYE0E0.book Page 1 Friday, November 14, 2003 11:47 AM
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DESCRIPTION
2-2
2
EAU10420
Right view1. Luggage strap holder (page 3-24)
2. Helmet holder (page 3-20)
3. Passenger seat lock (page 3-19)
4. Rear brake fluid reservoir (page 6-22)
5. Shock absorber assembly compression damping force adjusting screw
(page 3-22)
6. Engine oil filler cap (page 6-9)
7. Air filter element (page 6-14)
8. Engine oil level check window (page 6-9)9. Shock absorber assembly rebound damping force adjusting screw
(page 3-22)
10.Coolant reservoir (page 6-12)
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Page 24 of 104
INSTRUMENT AND CONTROL FUNCTIONS
3-10
32. Push the “SELECT” button to stop
the stopwatch.
3. Push the “SELECT” button again
to reset the stopwatch.
Split-time measurement
1. Push the “RESET” button to start
the stopwatch.
2. Push the “RESET” button to mea-
sure split-times. (The colon “:” will
start flashing.)
3. Push the “RESET” button to dis-
play the final split-time or push the
“SELECT” button to stop the stop-
watch and display total elapsed
time.
4. Push the “SELECT” button to reset
the stopwatch.
Coolant temperature display
The coolant temperature display indi-
cates the temperature of the coolant.
Push the “RESET” button to switch the
coolant temperature display to the air
intake temperature display.
NOTE:When the coolant temperature display
is selected, “C” is displayed for one
second, and then the coolant tempera-ture is displayed.CAUTION:
ECA10020
Do not operate the engine if it isoverheated.
Air intake temperature display
The air intake temperature display indi-
cates the temperature of the air drawn
into the air filter case. Push the “RE-
SET” button to switch the coolant tem-
perature display to the air intake
temperature display.NOTE:
Even if the air intake temperature
is set to be displayed, the coolant
temperature warning light comes
on when the engine overheats.
When the key is turned to “ON”,
the coolant temperature is auto-
matically displayed, even if the air
intake temperature was displayed
prior to turning the key to “OFF”.
When the air intake temperature
display is selected, “A” is displayedbefore the temperature.
Self-diagnosis devices
This model is equipped with a self-diag-
nosis device for various electrical cir-
cuits.
If any of those circuits are defective, the
engine trouble warning light will come
on, and then the right display will indi-
cate a two-digit error code (e.g., 11, 12,
13).
This model is also equipped with a self-
diagnosis device for the immobilizer
system.
If any of the immobilizer system circuits
are defective, the immobilizer system
indicator light will flash, and then the
right display will indicate a two-digit er-
ror code (e.g., 51, 52, 53).
NOTE:If the right display indicates error code
52, this could be caused by transpon-
der interference. If this error code ap-pears, try the following.
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-2
6
EAU17705
Periodic maintenance and lubrication chart NOTE:
The annual checks must be performed every year, except if a kilometer-based maintenance is performed in-
stead.
From 50000 km, repeat the maintenance intervals starting from 10000 km.
Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technicalskills.
NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (× 1000 km)
ANNUAL
CHECK
1 10203040
1*Fuel lineCheck fuel hoses for cracks or damage.√√√√ √
2*Spark plugsCheck condition.
Clean and regap.√√
Replace.√√
3*ValvesCheck valve clearance.
Adjust.Every 40000 km
4 Air filter elementReplace.√
5ClutchCheck operation.
Adjust.√√√√√
6*Front brakeCheck operation, fluid level and vehicle for fluid leakage.√√√√√ √
Replace brake pads. Whenever worn to the limit
7*Rear brakeCheck operation, fluid level and vehicle for fluid leakage.√√√√√ √
Replace brake pads. Whenever worn to the limit
8*Brake hosesCheck for cracks or damage.√√√√ √
Replace. Every 4 years
9*WheelsCheck runout and for damage.√√√√
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Page 52 of 104
PERIODIC MAINTENANCE AND MINOR REPAIR
6-4
6
23 Engine oilChange.
Check oil level and vehicle for oil leakage.√√√√√ √
24Engine oil filter car-
tridgeReplace.√√√
25*Cooling systemCheck coolant level and vehicle for coolant leakage.√√√√ √
Change. Every 3 years
26*Front and rear brake
switchesCheck operation.√√√√√ √
27Moving parts and ca-
blesLubricate.√√√√ √
28*Throttle grip housing
and cableCheck operation and free play.
Adjust the throttle cable free play if necessary.
Lubricate the throttle grip housing and cable.√√√√ √
29*Air induction systemCheck the air cut-off valve, reed valve, and hose for dam-
age.
Replace any damaged parts if necessary.√√√√ √
30*Muffler and exhaust
pipeCheck the screw clamp for looseness.√√√√√
31*EXUP systemCheck operation, cable free play and pulley position.√√√
32*Lights, signals and
switchesCheck operation.
Adjust headlight beam.√√√√√ √ NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (× 1000 km)
ANNUAL
CHECK
1 10203040U5VYE0E0.book Page 4 Wednesday, November 26, 2003 5:07 PM
Page 53 of 104
PERIODIC MAINTENANCE AND MINOR REPAIR
6-5
6
EAU18680
NOTE:
Air filter
This model’s air filter is equipped with a disposable oil-coated paper element, which must not be cleaned with com-
pressed 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
Regularly check and, if necessary, correct the brake fluid level.
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.
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Page 57 of 104
PERIODIC MAINTENANCE AND MINOR REPAIR
6-9
6
NOTE:If a torque wrench is not available when
installing a spark plug, a good estimate
of the correct torque is 1/4–1/2 turn
past finger tight. However, the spark
plug should be tightened to the speci-fied torque as soon as possible.CAUTION:
ECA10840
Do not use any tools to remove or in-
stall the spark plug cap, otherwise
the ignition coil coupler may get
damaged. The spark plug cap may
be difficult to remove because the
rubber seal on the end of the cap fits
tightly. To remove the spark plug
cap, simply twist it back and forth
while pulling it out; to install it, twistit back and forth while pushing it in.
EAU34002
Engine oil and oil filter
cartridge The engine oil level should be checked
before each ride. In addition, the oil
must be changed and the oil filter car-
tridge replaced at the intervals speci-
fied in the periodic maintenance and
lubrication chart.
To check the engine oil level
1. Place the vehicle on a level sur-
face and hold it in an upright posi-
tion.NOTE:
Make sure that the vehicle is positioned
straight up when checking the oil level.
A slight tilt to the side can result in an in-correct reading.
2. Start the engine, warm it up for
several minutes, and then turn it
off.
3. Wait a few minutes until the oil set-
tles, and then check the oil level
through the check window located
in the bottom-right side of the
crankcase.
NOTE:The engine oil should be between theminimum and maximum level marks.
4. If the engine oil is at or below the
minimum level mark, add sufficient
oil of the recommended type to
raise it to the correct level as fol-
lows.
a. Fit the rubber protector on the
special wrench.NOTE:The special wrench and rubber protec-tor are included in the owner’s tool kit.1. Engine oil level check window
2. Maximum level mark
3. Minimum level mark
4. Engine oil filler cap
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-10
6b. Remove the engine oil filler cap
with the special wrench as
shown.
c. Add sufficient oil of the recom-
mended type to raise it to the
correct level.
d. Install the engine oil filler cap
with the special wrench.
To change the engine oil (with or
without oil filter cartridge replace-
ment)
1. Remove cowling A. (See page
6-6.)2. Start the engine, warm it up for
several minutes, and then turn it
off.
3. Place an oil pan under the engine
to collect the used oil.
4. Remove the engine oil filler cap
with the special wrench.
5. Remove the engine oil drain bolt to
drain the oil from the crankcase.
NOTE:Skip steps 6–8 if the oil filter cartridge isnot being replaced.
6. Remove the oil filter cartridge with
an oil filter wrench.
NOTE:An oil filter wrench is available at aYamaha dealer.
7. Apply a thin coat of engine oil to
the O-ring of the new oil filter car-
tridge.
1. Engine oil filler cap
2. Special wrench
3. Rubber protector
1. Engine oil drain bolt
1. Oil filter wrench
2. Engine oil filter cartridge
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-11
6
NOTE:
Make sure that the O-ring is properlyseated.
8. Install the new oil filter cartridge
with an oil filter wrench, and then
tighten it to the specified torque
with a torque wrench.9. Install the engine oil drain bolt, and
then tighten it to the specified
torque.
NOTE:Check the washer for damage and re-place it if necessary.10. Add the specified amount of the
recommended engine oil, and then
install and tighten the oil filler cap
with the special wrench.
CAUTION:
ECA11620
In order to prevent clutch slip-
page (since the engine oil also
lubricates the clutch), do not
mix any chemical additives. Do
not use oils with a diesel speci-
fication of “CD” or oils of a high-
er quality than specified. In
addition, do not use oils labeled
“ENERGY CONSERVING II” or
higher.
Make sure that no foreign mate-rial enters the crankcase.
1. O-ring
1. Torque wrench
Tightening torque:
Oil filter cartridge:
17 Nm (1.7 m·kgf, 12 ft·lbf)
Tightening torque:
Engine oil drain bolt:
43 Nm (4.3 m·kgf, 31 ft·lbf)
Recommended engine oil:
See page 8-1.
Oil quantity:
Without oil filter cartridge replace-
ment:
2.90 L (3.07 US qt) (2.55 Imp.qt)
With oil filter cartridge replacement:
3.10 L (3.28 US qt) (2.73 Imp.qt)
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-14
6
EAU34020
Replacing the air filter element The air filter element should be re-
placed at the intervals specified in the
periodic maintenance and lubrication
chart. Replace the air filter element
more frequently if you are riding in un-
usually wet or dusty areas.
1. Remove the rider seat. (See page
3-19.)
2. Remove panels B and D. (See
page 6-6.)
3. Remove the bolts.
4. Lift the front of the fuel tank, and
then tilt it back and away from the
air filter case. (Do not disconnect
the fuel hoses!)
WARNING
EWA10410
Make sure that the fuel tank is
well supported.
Do not tilt or pull the fuel tank
too much, otherwise the fuel
hoses may come loose, whichcould cause fuel leakage.
5. Remove the rubber cap, and then
remove the air filter case cover by
removing the screws.
CAUTION:
ECA12880
When removing the air filter case
cover, be careful not to allow foreign
objects to drop into the air intakemanifold.
1. Bolt
1. Rubber cap
1. Screw
2. Air filter case cover
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