Yamaha R1 2004 ServiceManual
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2-3 ENGINE SPECIFICATIONSSPEC ItemStandardLimit Oil filter Oil filter type Bypass valve opening pressure Paper 80 120 kPa (0.8 1.2 kg / cm2, 0.8 1.2 bar, 11.6 17.4 psi) Oil pump Oil pump type Inner-rotor-to-outer-rotor-tip clearance Outer-rotor-to-oil-pump-housing clearance Trochoid 0.01 0.10 mm (0.0004 0.0039 in) 0.09 0.15 mm (0.00035 0.0059 in) 0.18 mm (0.0071 in) 0.22 mm (0.0087 in) Cooling system Radiator capacity Radiator cap opening pressure Radiator core Width Height Depth Coolant reservoir Capacity Water pump Water pump type Reduction ratio Max. impeller shaft tilt 2.51 L (2.21 Imp qt, 2.65 US qt) 108 137 kPa (1.08 1.37 kg / cm2, 1.0 1.3 bar, 15.6 19.9 psi) 380 mm (14.96 in) 258 mm (10.2 in) 24 mm (0.94 in) 0.25 L (0.22 Imp qt, 0.26 US qt) Single suction centrifugal pump 65 / 43 25 / 32 (1.181) 0.15 mm (0.006 in) Starting system typeElectric starter Spark plugs Model (manufacturer) quantity Spark plug gap CR9EK (NGK) 4 0.6 0.7 mm (0.0236 0.0276 in) Cylinder head Volume Max. warpage 12.5 13.1 cm3 (0.76 0.80 cu.in) 0.10 mm (0.0039 in)
2-4 ENGINE SPECIFICATIONSSPEC ItemStandardLimit Camshafts Drive system Camshaft cap inside diameter Camshaft journal diameter Camshaft-journal-to-camshaft- cap clearance Intake camshaft lobe dimensions Measurement A Measurement B Exhaust camshaft lobe dimensions Measurement A Measurement B Max. camshaft runout Chain drive (right) 22.500 22.521 mm (0.8858 0.8867 in) 22.459 22.472 mm (0.8842 0.8847 in) 0.028 0.062 mm (0.0011 0.0024 in) 32.85 32.95 mm (1.293 1.297 in) 25.14 25.24 mm (0.990 0.994 in) 30.75 30.85 mm (1.211 1.215 in) 23.09 23.19 mm (0.909 0.913 in) 32.75 mm (1.289 in) 25.04 mm (0.986 in) 30.65 mm (1.207 in) 22.99 mm (0.905 in) 0.03 mm (0.0012 in)
2-5 ENGINE SPECIFICATIONSSPEC Head Diameter Face Width Seat Width Margin Thickness ItemStandardLimit Timing chain Model / number of links Tensioning system RH2020 / 122 Automatic Valves, valve seats, valve guides Valve clearance (cold) Intake Exhaust Valve dimensions 0.11 0.20 mm (0.0043 0.0079 in) 0.21 0.25 mm (0.0083 0.0098 in) Valve head diameter A Intake Exhaust Valve face width B Intake Exhaust Valve seat width C Intake Exhaust Valve margin thickness D Intake Exhaust Valve stem diameter Intake Exhaust Valve guide inside diameter Intake Exhaust Valve-stem-to-valve-guide clearance Intake Exhaust Valve stem runout Valve seat width Intake Exhaust 23.4 23.6 mm (0.9213 0.9291 in) 24.9 25.1 mm (0.9803 0.9882 in) 1.76 2.90 mm (0.0693 0.1142 in) 1.76 2.90 mm (0.0693 0.1142 in) 0.9 1.1 mm (0.0354 0.0433 in) 0.9 1.1 mm (0.0354 0.0433 in) 0.5 0.9 mm (0.0197 0.0354 in) 0.5 0.9 mm (0.0197 0.0354 in) 3.975 3.990 mm (0.1565 0.1571 in) 4.460 4.475 mm (0.1756 0.1762 in) 4.000 4.012 mm (0.1575 0.1580 in) 4.500 4.512 mm (0.1772 0.1776 in) 0.010 0.037 mm (0.0004 0.0015 in) 0.025 0.052 mm (0.0010 0.0020 in) 0.9 1.1 mm (0.0354 0.0433 in) 0.9 1.1 mm (0.0354 0.0433 in) 1.6 mm (0.06 in) 1.6 mm (0.06 in) 0.5 mm (0.02 in) 0.5 mm (0.02 in) 3.945 mm (0.1553 in) 4.425 mm (0.1742 in) 4.050 mm (0.1594 in) 4.550 mm (0.1791 in) 0.08 mm (0.0032 in) 0.10 mm (0.0039 in) 0.01 mm (0.0004 in) 1.6 mm (0.06 in) 1.6 mm (0.06 in)
2-6 ENGINE SPECIFICATIONSSPEC ItemStandardLimit Valve springs Free length Intake Exhaust Installed length (valve closed) Intake Exhaust Compressed spring force (installed) Intake Exhaust Spring tilt Intake Exhaust Winding direction (top view) Intake Exhaust 39.3 mm (1.55 in) 39.3 mm (1.55 in) 32.7 mm (1.29 in) 32.8 mm (1.29 in) 145.9 167.9 N (14.88 17.12 kg, 32.80 37.74 lb) 164.1 188.9 N (16.73 19.26 kg, 36.89 42.46 lb) Clockwise Clockwise37.3 mm (1.47 in) 37.3 mm (1.47 in) 2.5/ 1.7 mm (0.07 in) 2.5/ 1.7 mm (0.07 in) Cylinders Cylinder arrangement Bore stroke Compression ratio Bore Max. out-of-round Forward-inclined, parallel 4-cylinder 77.0 mm 53.6 mm (3.03 2.11 in) 12.4 : 1 77.00 77.01 mm (3.0315 3.0319 in) 0.005 mm (0.0002 in)
2-7 ENGINE SPECIFICATIONSSPEC ItemStandardLimit Piston Piston-to-cylinder clearance Diameter D Height H Piston pin bore (in the piston) Diameter Offset Offset direction Piston pins Outside diameter Piston-pin-to-piston-pin-bore clearance Piston rings Top ring Ring type Dimensions (B T) End gap (installed) Ring side clearance 2nd ring Ring type Dimensions (B T) End gap (installed) Ring side clearance Oil ring Dimensions (B T) End gap (installed) 0.010 0.035 mm (0.0004 0.0014 in) 76.975 76.990 mm (3.0305 3.0311 in) 5 mm (0.20 in) 17.002 17.013 mm (0.6694 0.6698 in) 0.5 mm (0.0197 in) Intake side 16.991 17.000 mm (0.6689 0.6693 in) 0.002 0.022 mm (0.0001 0.0009 in) Barrel 0.90 2.75 mm (0.04 0.11 in) 0.15 0.25 mm (0.0059 0.0098 in) 0.030 0.065 mm (0.0012 0.0026 in) Taper 0.80 2.75 mm (0.03 0.11 in) 0.30 0.45 mm (0.0118 0.0177 in) 0.020 0.055 mm (0.0008 0.0022 in) 1.50 2.25 mm (0.06 0.09 in) 0.10 0.40 mm (0.0039 0.0158 in)0.120 mm (0.0047 in) 17.043 mm (0.6710 in) 16.971 mm (0.6682 in) 0.072 mm (0.0028 in) 0.50 mm (0.0197 in) 0.115 mm (0.0045 in) 0.80 mm (0.0315 in) 0.115 mm (0.0045 in)
2-8 ENGINE SPECIFICATIONSSPEC ItemStandardLimit Connecting rods Crankshaft-pin-to-big-end-bearing clearance Bearing color code 0.034 0.058 mm (0.0013 0.0023 in) 1 = Blue 2 = Black 3 = Brown 4 = Green0.09 mm (0.0035 in) Crankshaft Width A Width B Max. runout C Big end side clearance D Crankshaft-journal-to-crankshaft- journal-bearing clearance Bearing color code 55.20 56.60 mm (2.17 2.23 in) 298.8 300.7 mm (11.76 11.84 in) 0.160 0.262 mm (0.0063 0.0103 in) 0.014 0.037 mm (0.0006 0.0015 in) 0 = White 1 = Blue 2 = Black 3 = Brown 4 = Green 0.03 mm (0.0012 in) 0.10 mm (0.0039 in)
2-9 ENGINE SPECIFICATIONSSPEC ItemStandardLimit Clutch Clutch type Clutch release method Clutch release method operation Operation Clutch cable free play (at the end of the clutch lever) Friction plates Color code Thickness Plate quantity Color code Thickness Plate quantity Color code Thickness Plate quantity Clutch plates Thickness Plate quantity Max. warpage Clutch springs Free length Spring quantity Wet, multiple disc Outer pull, rack and pinion pull Cable operation Left-hand operation 10 15 mm (0.39 0.59 in) Purple 2.9 3.1 mm (0.114 0.122 in) 7 Green 2.9 3.1 mm (0.114 0.112 in) 1 – 2.9 3.1 mm (0.114 0.112 in) 1 1.9 2.1 mm (0.07 0.08 in) 8 52.5 mm (2.07 in) 6 2.8 mm (0.110 in) 2.8 mm (0.110 in) 2.8 mm (0.110 in) 0.1 mm (0.0039 in) 49.9 mm (1.96 in)
2-10 ENGINE SPECIFICATIONSSPEC ItemStandardLimit Transmission Transmission type Primary reduction system Primary reduction ratio Secondary reduction system Secondary reduction ratio Operation Gear ratios 1st gear 2nd gear 3rd gear 4nd gear 5th gear 6th gear Max. main axle runout Max. drive axle runout Constant mesh, 6-speed Spur gear 65 / 43 (1.512) Chain drive 45 / 17 (2.647) Left-foot operation 38 / 15 (2.533) 33 / 16 (2.063) 37 / 21 (1.762) 35 / 23 (1.522) 30 / 22 (1.364) 33 / 26 (1.269) 0.08 mm (0.0032 in) 0.08 mm (0.0032 in) Shifting mechanism Shift mechanism type Max. shift fork guide bar bending Shift drum / Guide bar 0.10 mm (0.0039 in) Air filter typeOil coated paper element Fuel pump Pump type Model (manufacturer) Output pressure Electrical 5PW (DENSO) 294 kPa (2.94 kg / cm 2, 2.94 bar, 42.6 psi) Throttle position sensor Resistance Output voltage (at idle) 4.9 5.1 kΩ at 20C (68F) 0.63 0.73 V Throttle bodies Model (manufacturer) quantity Intake vacuum pressure Throttle cable free play (at the flange 45EIDW (MIKUNI) 2 22 kPa (165 mmHg, 6.4966 inHg) 3 5 mm (0.12 0.20 in) of the throttle grip) ID mark Throttle valve size 5VY1 00 (USA) 5VY5 10 (CAL) #100
2-11 CHASSIS SPECIFICATIONSSPEC CHASSIS SPECIFICATIONS ItemStandardLimit Frame Frame type Caster angle Trail Diamond 24 97 mm (3.82 in) Front wheel Wheel type Rim Size Material Wheel travel Wheel runout Max. radial wheel runout Max. lateral wheel runout Cast wheel 17 M / C MT3.50 Aluminum 120 mm (4.72 in) 1 mm (0.04 in) 0.5 mm (0.02 in) Rear wheel Wheel type Rim Size Material Wheel travel Wheel runout Max. radial wheel runout Max. lateral wheel runout Cast wheel 17 M / C MT6.00 Aluminum 130 mm (5.12 in) 1 mm (0.04 in) 0.5 mm (0.02 in) Front tire Tire type Size Model (manufacturer) Tire pressure (cold) 0 90 kg (0 198 lb) 90 202 kg (198 445 lb) High-speed riding Min. tire tread depth Tubeless 120 / 70 ZR17 M / C (58W) Pilot POWER C (MICHELIN) D218FL (DUNLOP) 250 kPa (2.5 kgf / cm 2, 2.5 bar, 35.6 psi) 250 kPa (2.5 kgf / cm2, 2.5 bar, 35.6 psi) 250 kPa (2.5 kgf / cm2, 2.5 bar, 35.6 psi) 1.6 mm (0.06 in) Rear tire Tire type Size Model (manufacturer) Tire pressure (cold) 0 90 kg (0 198 lb) 90 202 kg (198 445 lb) High-speed riding Min. tire tread depth Tubeless 190 / 50 ZR17 M / C (73W) Pilot POWER G (MICHELIN) D218L (DUNLOP) 290 kPa (2.9 kgf / cm 2, 2.9 bar, 41.3 psi) 290 kPa (2.9 kgf / cm2, 2.9 bar, 41.3 psi) 290 kPa (2.9 kgf / cm2, 2.9 bar, 41.3 psi) 1.6 mm (0.06 in)
2-12 CHASSIS SPECIFICATIONSSPEC ItemStandardLimit Front brakes Brake type Operation Recommended fluid Brake lever free play Brake discs Diameter thickness Min. thickness Max. deflection Brake pad lining thickness (inner) Brake pad lining thickness (outer) Master cylinder inside diameter Caliper cylinder inside diameter Dual disc brake Right hand operation DOT 4 2.3 11.5 mm (0.09 0.45 in) 320 4.5 mm (12.60 0.18 in) 4.5 mm (0.18 in) 4.5 mm (0.18 in) 14 mm (0.55 in) 30.1 mm and 27 mm (1.19 in and 1.06 in) 4.0 mm (0.16 in) 0.1 mm (0.004 in) 0.5 mm (0.02 in) 0.5 mm (0.02 in) Rear brake Brake type Operation Recommended fluid Brake pedal freeplay Brake discs Diameter thickness Min. thickness Max. deflection Brake pad lining thickness (inner) Brake pad lining thickness (outer) Master cylinder inside diameter Caliper cylinder inside diameter Single disc brake Right foot operation DOT 4 4.3 9.3 mm (0.17 0.37 in) 220 5 mm (8.66 0.20 in) 6.0 mm (0.24 in) 6.0 mm (0.24 in) 12.7 mm (0.5 in) 31.8 mm (1.25 in) 4.5 mm (0.18 in) 0.15 mm (0.006 in) 1.0 mm (0.04 in) 1.0 mm (0.04 in)