Yamaha R1 2004 ServiceManual

3-14
ADJUSTING THE VALVE CLEARANCE
CHK
ADJ
NOTE:
NOTE:
c. Round off the original valve pad number ac-
cording to the following table.
Last digit
Rounded value
0 or 20
55
810
EXAMPLE:
Original valve pad number 
= 148 (thickness =1.48 mm (0.058 in))
Rounded value = 150
d. Locate the rounded number of the original
valve pad and the measured valve clearance
in the valve pad selection table. The point
where the column and row intersect is the
new valve pad number.
The new valve pad number is only an approxi-...

3-15
ADJUSTING THE VALVE CLEARANCE
CHK
ADJ
NOTE:

Refer to “ASSEMBLING AND ADJUSTING
THE ENGINE – CYLINDER HEAD AND CAM-
SHAFT” in chapter 5.

Lubricate the camshaft bearings, camshaft
lobes and camshaft journals.

First, install the exhaust camshaft.

Align the camshaft marks with the camshaft
cap marks.

Turn the crankshaft counterclockwise several
full turns to seat the parts.
g. Measure the valve clearance again.
h. If the valve clearance is still out of specifica-
tion, repeat all of the valve...

3-16
ADJUSTING THE VALVE CLEARANCE
CHK
ADJ
VALVE CLEARANCE (cold):
  0.11  0.20 mm (0.0043  0.0079 in)
Example: Installed is 175
  Measured clearance is 0.27 mm (0.0106 in)
Replace 175 pad with 185 pad
  Pad number: (example)
  Pad No.175 = 1.75 mm (0.0689 in)
  Pad No.185 = 1.85 mm (0.0728 in)
MEASURED
CLEARANCEINSTALLED PAD NUMBER
VALVE CLEARANCE (cold):
  0.21  0.25 mm (0.0083  0.0098 in)
Example: Installed is 175
  Measured clearance is 0.35 mm (0.0138 in)
Replace 175 pad with 185 pad
  Pad...

3-17
ADJUSTING THE VALVE CLEARANCE /
SYNCHRONIZING THE THROTTLE BODIESCHK
ADJ
NOTE:
NOTE:
NOTE:
7. Install:

all removed parts
For installation, reverse the removal procedure.
SYNCHRONIZING THE THROTTLE BODIES
Prior to synchronizing the throttle bodies, the
valve clearance and the engine idling speed
should be properly adjusted and the ignition tim-
ing should be checked.
1. Stand the motorcycle on a level surface.
Place the motorcycle on a suitable stand.
2. Remove:

rider seat
Refer to “SEATS”.

fuel...

3-18
SYNCHRONIZING THE THROTTLE BODIES
CHK
ADJ
NOTE:
CAUTION:
NOTE: 5. Install:

fuel tank
Refer to “FUEL TANK”.
6. Start the engine and let it warm up for several
minutes.
7. Measure:

engine idling speed
Out of specification 
 Adjust.
Refer to “ADJUSTING THE ENGINE IDLING
SPEED”.
Engine idling speed
1,150  1,250 r / min
8. Adjust:

throttle body synchronization
a. With throttle body #3 as standard, adjust
throttle bodies #1, #2, and #4 using the air
screws 
1.

After each step, rev the engine two or...

3-19
SYNCHRONIZING THE THROTTLE BODIES /
ADJUSTING THE EXHAUST GAS VOLUMECHK
ADJ
NOTE:
NOTE: 9. Measure:

engine idling speed
Out of specification 
 Adjust.
Make sure that the vacuum pressure is within
specification.
10. Stop the engine and remove the measuring
equipment.
11. Adjust:

throttle cable free play
Refer to “ADJUSTING THE THROTTLE
CABLE FREE PLAY”.
Throttle cable free play 
(at the flange of the throttle grip)
3  5 mm (0.12  0.20 in)
13. Install:

synchronizing hoses

fuel tank
Refer to...

3-20
ADJUSTING THE EXHAUST GAS VOLUME
CHK
ADJ
NOTE:
NOTE: 3. Using the “SELECT” button, select either the
Co adjustment mode 
1 (which appears as
“Co”) or the diagnosis mode (which appears
as “dIAG”).
4. After “Co” appears as a result of pressing the
“SELECT” button, simultaneously press the
“SELECT” and “RESET” buttons for 2 se-
conds or more to excute the selection.
5. Press the “SELECT” and “RESET” buttons to
select the cylinder 
2.

The adjustment cylinder appears on the clock
LCD.
“RESET” button =...

3-21
ADJUSTING THE ENGINE IDLING SPEED
CHK
ADJ
NOTE:
a
b
EAS00052
ADJUSTING THE ENGINE IDLING SPEED
Prior to adjusting the engine idling speed, the
throttle bodies synchronization should be ad-
justed properly, and the engine should have ad-
equate compression.
1. Start the engine and let it warm up for several
minutes.
2. Install:

digital tachometer
(near the spark plug)
3. Check:

engine idling speed
Out of specification 
 Adjust.
Engine idling speed
1,150  1,250 r / min
4. Adjust:

engine idling...

3-22
ADJUSTING THE THROTTLE CABLE FREE PLAY
CHK
ADJ
NOTE:
a
b
WARNING
EAS00056
ADJUSTING THE THROTTLE CABLE FREE 
PLAY
Prior to adjusting the throttle cable free play, the
engine idling speed should be adjusted proper-
ly.
1. Check:

throttle cable free play 
a
Out of specification 
 Adjust.
Throttle cable free play (at the 
flange of the throttle grip)
3  5 mm (0.12  0.20 in)
2. Adjust:

throttle cable free play
Handlebar side
a. Loosen the locknut 
1.
b. Turn the adjusting nut 
2 in direction a or b...

3-23
CHECKING THE SPARK PLUGS
CHK
ADJ
CAUTION:
EAS00059
CHECKING THE SPARK PLUGS
The following procedure applies to all of the
spark plugs.
1. Remove:

side cowlings

bottom cowlings
Refer to “COWLINGS”.
2. Remove:

radiator upper bolts

radiator lower bolt
Refer to “RADIATOR” in chapter 6.
3. Remove:

ignition coils

spark plugs
Before removing the spark plugs, blow away
any dirt accumulated in the spark plug wells
with compressed air to prevent it from fal-
ling into the cylinders.
4. Check:

spark...