Yamaha R1 2004 ServiceManual

							3-54
ADJUSTING THE FRONT FORK LEGS
CHK
ADJ
WARNING
CAUTION:
a
b
CAUTION:
EAS00155
ADJUSTING THE FRONT FORK LEGS
The following procedure applies to both of the
front fork legs.

Always adjust both front fork legs evenly.
Uneven adjustment can result in poor han-
dling and loss of stability.

Securely support the motorcycle so that
there is no danger of it falling over.
Spring preload

Grooves are provided to indicate the ad-
justment position.

Never go beyond the maximum or mini-
mum adjustment positions.
1. Adjust:

spring preload
a. Turn the adjusting bolt 
1 in direction a or
b.
Direction
Spring preload is
increased (suspension is
harder).
Direction
Spring preload is
decreased (suspension 
is softer).
Adjusting positions
Minimum: 8
Standard: 4.5
Maximum: 1
Rebound damping
Never go beyond the maximum or minimum
adjustment positions. 
						

							3-55
ADJUSTING THE FRONT FORK LEGS
CHK
ADJ
a
b
CAUTION:
a
b
1. Adjust:

rebound damping
a. Turn the adjusting screw 
1 in direction a or
b.
Direction
Rebound damping is
increased (suspension is
harder).
Direction
Rebound damping is
decreased (suspension 
is softer).
Adjusting positions
Minimum: 26 clicks in direction 
b *
Standard: 10 clicks in direction 
b *
Maximum: 1 clicks in direction 
b *
* with the adjusting screw fully 
turned-in direction 
a
Compression damping
Never go beyond the maximum or minimum
adjustment positions.
1. Adjust:

compression damping
a. Turn the adjusting screw 
1 in direction a or
b.
Direction
Compression damping is
increased (suspension is
harder).
Direction
Compression damping is
decreased (suspension 
is softer).
Adjusting positions
Minimum: 25 clicks in direction 
b *
Standard: 10 clicks in direction 
b *
Maximum: 1 clicks in direction 
b *
* with the adjusting screw fully 
turned-in direction 
a 
						

							3-56
ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY
CHK
ADJ
WARNING
CAUTION:
a
b
CAUTION:
EAS00158
ADJUSTING THE REAR SHOCK 
ABSORBER ASSEMBLY
Securely support the motorcycle so that
there is no danger of it falling over.
Spring preload
Never go beyond the maximum or minimum
adjustment positions.
1. Adjust:

spring preload
a. Adjust the spring preload with the special
wrench and extension bar included in the
owner’s tool kit.
b. Turn the adjusting ring 
1 in direction a or
b.
c. Align the desired position on the adjusting
ring with the stopper 
2.
Direction
Spring preload is
increased (suspension is
harder).
Direction
Spring preload is
decreased (suspension 
is softer).
Adjusting positions
Minimum: 1
Standard: 4
Maximum: 9
Rebound damping
Never go beyond the maximum or minimum
adjustment positions. 
						

							3-57
ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY
CHK
ADJ
a
b
CAUTION:
a
b
1. Adjust:

rebound damping
a. Turn the adjusting screw 
1 in direction a or
b.
Direction
Rebound damping is
increased (suspension is
harder).
Direction
Rebound damping is
decreased (suspension 
is softer).
Adjusting positions
Minimum: 20 clicks in direction 
b *
Standard: 17 clicks in direction 
b *
Maximum: 1 clicks in direction 
b *
* with the adjusting screw fully 
turned-in direction 
a
Compression damping
Never go beyond the maximum or minimum
adjustment positions.
1. Adjust:

compression damping
a. Turn the adjusting screw 
1 in direction a or
b.
Direction
Compression damping is
increased (suspension is
harder).
Direction
Compression damping is
decreased (suspension 
is softer).
Adjusting positions
Minimum: 20 clicks in direction 
b *
Standard: 12 clicks in direction 
b *
Maximum: 1 clicks in direction 
b *
* with the adjusting screw fully 
turned-in direction 
a 
						

							3-58
CHECKING THE TIRES
CHK
ADJ
WARNING
WARNING
EAS00162
CHECKING THE TIRES
The following procedure applies to both of the
tires.
1. Check:

tire pressure
Out of specification 
 Regulate.

The tire pressure should only be checked
and regulated when the tire temperature
equals the ambient air temperature.

The tire pressure and the suspension must
be adjusted according to the total weight
(including cargo, rider, passenger and ac-
cessories) and the anticipated riding
speed.

Operation of an overloaded motorcycle
could cause tire damage, an accident or an
injury.
NEVER OVERLOAD THE MOTORCYCLE.
Basic
weight
(with oil
and a full
fuel tank)
193 kg (425 lb)
194 kg (428 lb) for CAL
Maximum
load*202 kg (445 lb)
201 kg (443 lb) for CAL
Cold tire
pressureFrontRear
Up to 
90 kg
load*250 kPa 
(2.5 kgf / cm2,
2.5 bar,
35.6 psi)
290 kPa 
(2.9 kgf / cm2,
2.9 bar,
41.3 psi)
90 kg 

maximum 
load*250 kPa 
(2.5 kgf / cm2,
2.5 bar,
35.6 psi)
290 kPa 
(2.9 kgf / cm2,
2.9 bar,
41.3 psi)
High-
speed 
riding250 kPa 
(2.5 kgf / cm2,
2.5 bar,
35.6 psi)
290 kPa 
(2.9 kgf / cm2,
2.9 bar,
41.3 psi)
* Total weight of rider, passenger, cargo and ac-
cessories
It is dangerous to ride with a worn-out tire.
When the tire tread reaches the wear limit,
replace the tire immediately. 
						

							3-59
AB
CHECKING THE TIRES
CHK
ADJ
WARNING
WARNING
2. Check:

tire surfaces
Damage / wear 
 Replace the tire.
Minimum tire tread depth
1.6 mm (0.06 in)
1Tire tread depth
2Sidewall
3Wear indicator

Do not use a tubeless tire on a wheel de-
signed only for tube tires to avoid tire fail-
ure and personal injury from sudden defla-
tion.

When using a tube tire, be sure to install the
correct tube.

Always replace a new tube tire and a new
tube as a set.

To avoid pinching the tube, make sure the
wheel rim band and tube are centered in the
wheel groove.

Patching a punctured tube is not recom-
mended. If it is absolutely necessary to do
so, use great care and replace the tube as
soon as possible with a good quality re-
placement.
ATire
BWheel
Tube wheelTube tire only
T beless wheelTube or tubelessTubeless wheeltire
After extensive tests, the tires listed below
have been approved by Yamaha Motor Co.,
Ltd. for this model. The front and rear tires
should always be by the same manufacturer
and of the same design. No guarantee con-
cerning handling characteristics can be giv-
en if a tire combination other than one ap-
proved by Yamaha is used on this
motorcycle. 
						

							3-60
CHECKING THE TIRES / CHECKING THE WHEELS
CHK
ADJ
WARNING
NOTE:
WARNING
NOTE: Front tire
Manufacturer
SizeModel
DUNLOP120 / 70ZR 17
M / C (58W)D218FL
MICHELIN120 / 70ZR 17
M / C (58W)Pilot
POWER C
Rear tire
Manufacturer
SizeModel
DUNLOP190 / 50ZR 17
M / C (73W)D218L
MICHELIN190 / 50ZR 17
M / C (73W)Pilot
POWER G
New tires have a relatively low grip on the
road surface until they have been slightly
worn. Therefore, approximately 100 km
should be traveled at normal speed before
any high-speed riding is done.
For tires with a direction of rotation mark 
1:

Install the tire with the mark pointing in the
direction of wheel rotation.

Align the mark 
2 with the valve installation
point.
EAS00168
CHECKING THE WHEELS
The following procedure applies to both of the
wheels.
1. Check:

wheel
Damage / out-of-round 
 Replace.
Never attempt to make any repairs to the
wheel.
After a tire or wheel has been changed or re-
placed, always balance the wheel. 
						

							3-61
CHECKING AND LUBRICATING THE CABLES /
LUBRICATING THE LEVERS AND PEDALS /
LUBRICATING THE SIDESTAND / LUBRICATING THE REAR SUSPENSIONCHK
ADJ
WARNING
NOTE:
EAS00170
CHECKING AND LUBRICATING THE 
CABLES
The following procedure applies to all of the in-
ner and outer cables.
Damaged outer cable may cause the cable to
corrode and interfere with its movement. Re-
place damaged outer cable and inner cables
as soon as possible.
1. Check:

outer cable
Damage 
 Replace.
2. Check:

cable operation
Rough movement 
 Lubricate.
Recommended lubricant
Engine oil or a suitable cable 
lubricant
Hold the cable end upright and pour a few drops
of lubricant into the cable sheath or use a suit-
able lubricating device.
EAS00171
LUBRICATING THE LEVERS AND PEDALS
Lubricate the pivoting point and metal-to-metal
moving parts of the levers and pedals.
Recommended lubricant
Lithium-soap-based grease
EAS00172
LUBRICATING THE SIDESTAND
Lubricate the pivoting point and metal-to-metal
moving parts of the sidestand.
Recommended lubricant
Lithium-soap-based grease
EAS00174
LUBRICATING THE REAR SUSPENSION
Lubricate the pivoting point and metal-to-metal
moving parts of the rear suspension.
Recommended lubricant
Molybdenum-disulfide grease 
						

							3-62
CHECKING AND CHARGING THE BATTERY
CHK
ADJ
WARNING
CAUTION:
EAS00178
ELECTRICAL SYSTEM
CHECKING AND CHARGING THE BATTERY
Batteries generate explosive hydrogen gas
and contain electrolyte which is made of poi-
sonous and highly caustic sulfuric acid.
Therefore, always follow these preventive
measures:

Wear protective eye gear when handling or
working near batteries.

Charge batteries in a well-ventilated area.

Keep batteries away from fire, sparks or
open flames (e.g., welding equipment,
lighted cigarettes).

DO NOT SMOKE when charging or han-
dling batteries.

KEEP BATTERIES AND ELECTROLYTE
OUT OF REACH OF CHILDREN.

Avoid bodily contact with electrolyte as it
can cause severe burns or permanent eye
injury.
FIRST AID IN CASE OF BODILY CONTACT:
EXTERNAL

Skin – Wash with water.

Eyes – Flush with water for 15 minutes and
get immediate medical attention.
INTERNAL

Drink large quantities of water or milk fol-
lowed with milk of magnesia, beaten egg or
vegetable oil. Get immediate medical atten-
tion.

This is a sealed battery. Never remove the
sealing caps because the balance between
cells will not be maintained and battery per-
formance will deteriorate.

Charging time, charging amperage and
charging voltage for an MF battery are dif-
ferent from those of conventional batter-
ies. The MF battery should be charged as
explained in the charging method illustra-
tions. If the battery is overcharged, the
electrolyte level will drop considerably.
Therefore, take special care when charging
the battery. 
						

							3-63
Relationship between the open-circuit voltage
and the charging time at 20C
Open-circuit voltage (V)
These values vary with the temperature, the condition of
the battery plates, and the electrolyte level. 13.0
12.5
12.0
11.5
5 6.5 10
Charging time (hours)
Ambient
temperature
20C
Open-circuit voltage (V)
Charging condition of the battery (%)
CHECKING AND CHARGING THE BATTERY
CHK
ADJ
NOTE:
CAUTION:
NOTE:
Since MF batteries are sealed, it is not possible
to check the charge state of the battery by mea-
suring the specific gravity of the electrolyte.
Therefore, the charge of the battery has to be
checked by measuring the voltage at the battery
terminals.
1. Remove:

rider seat
Refer to “SEATS”.
2. Disconnect:

battery leads
(from the battery terminals)
First, disconnect the negative battery lead
1, and then the positive battery lead 2.
3. Remove:

battery
4. Check:

battery charge
a. Connect a pocket tester to the battery termi-
nals.
Pocket tester
90890-03112, YU-3112
Positive tester probe 
 
positive battery terminal
Negative tester probe 
 
negative battery terminal

The charge state of an MF battery can be
checked by measuring its open-circuit voltage
(i.e., the voltage when the positive battery ter-
minal is disconnected).

No charging is necessary when the open-cir-
cuit voltage equals or exceeds 12.8 V.
b. Check the charge of the battery, as shown in
the charts and the following example.
Example
c. Open-circuit voltage = 12.0 V
d. Charging time = 6.5 hours
e. Charge of the battery = 20 
 30%