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YEC '04 YZF-R1, Kit Manual

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YEC '04 YZF-R1 Kit Manual Download Page 6

- 2 -

2

Kit  Parts

2-1  Basic Kit Set Contents

Spark plug set
Head gasket (0.30 mm)
High lift camshaft (INT, EXT)
Valve spring set
Funnel set
AIS plug set
Clutch spring set
ACM rotor
Wire harness set
Engine control unit
Kit manual

Note:

The part marked [ * ] at the top of the parts list is included in the kit, but if it is 
specifically needed, it is available from Yamaha authorized dealers.

2-2 Engine Parts
1.  Maintenance set (5VY-MAINT-70)

Parts List

No. PART 

No.  PART 

NAME 

Q’TY 

REMARKS

*

1

5VY-11181-00

GSKT., H/C

3

*

2

5VY-11351-00

GSKT, 1

3

*

3

5VY-11603-00

RING SET

12

*

4

5VY-1165A-01

BOLT, CON-ROD

12

*

5

90468-12069

CIRCLIP

12

*

6

4TV-12119-00

SEAL, STEM 

36

INT

*

7

4SV-12119-00

SEAL, STEM 

24

EXT

*

8

5VY-13414-00

GSKT, STRAINER

3

*

9

5VY-15451-00

GSKT COVER1

3

ACM

*

10

5VY-15461-00

GSKT COVER2 

3

CLUTCH

*

11

5VY-15456-00

GSKT 1 

3

PICK UP

*

12

5VY-15462-00

GSKT COVER3 

3

BREATHER

*

13

90179-20007

NUT

3

CLUTCH BOSS

*

14

90215-30233

WASHER LOCK 

3

SPROCKET

*

15

93102-40330

OIL SEAL 

3

DRIVE AXLE

*

16

90110-06027

BOLT

9

MAIN AXLE

Summary of Contents for '04 YZF-R1

Page 1: ... 04 YZF R1 KIT MANUAL The Performance Edge for top ranking riders ...

Page 2: ...parts are intended for racing alone They are not to be used in any circumstances on public roads The specifications and methods of use of these kit parts and the contents of the present manual are subject to improvement changes without notice This manual is intended for persons with knowledge and experience of motorcycles Please refer to the service manual for information on part assembly and main...

Page 3: ...ch Boss 10 11 ACM Rotor 11 12 Engine Control Unit ECU 12 13 Wire Harness 23 14 Headlight Harness Set 5VY F4350 70 23 2 3 Chassis Parts 25 15 Oil Catcher Tank Set 5VY C1707 70 25 16 Chassis Protector Set 5VY C117G 70 26 17 Rear Suspension Spring 26 18 Front Fork Spring Set 27 19 Front Disk Assembly 5VY 2581T 70 28 20 Front Wheel Attachment Set 29 21 Rear Arm Attachment Set Rear Wheel Attachment Set...

Page 4: ...3 3 4 Installing the piston piston ring and connecting rod 45 3 5 Crankcase installation 47 3 6 Cylinder head tightening calibrated wrench tightening method 48 3 7 Camshaft installation 49 3 8 Cam chain tensioner installation 50 3 9 Engine mounting 51 3 10 Front axle installation 52 Headlight cord wiring diagram 56 2004 YZF R1 Wiring Diagram 57 ...

Page 5: ...286 8 5 33 8 mm Camshaft EXT Nominal Major axis 5VY 00 284 7 5 30 8 mm 5VY 70 288 8 5 31 8 mm Valve timing event angle INT EXT 105 105 105 105 Valve clearance INT EXT 0 17 mm 0 23 mm 0 27 mm 0 33 mm Throttle body MIKUNI Throttle valve passage diameter 45 0 mm Exhaust system 4 2 1 type 1 2 3 4 connected Transmission 1st 2nd 3rd 4th 5th 6th Constant mesh 6 speed box 38 15 2 533 33 16 2 063 37 21 1 7...

Page 6: ...rts 1 Maintenance set 5VY MAINT 70 Parts List No PART No PART NAME Q TY REMARKS 1 5VY 11181 00 GSKT H C 3 2 5VY 11351 00 GSKT 1 3 3 5VY 11603 00 RING SET 12 4 5VY 1165A 01 BOLT CON ROD 12 5 90468 12069 CIRCLIP 12 6 4TV 12119 00 SEAL STEM 36 INT 7 4SV 12119 00 SEAL STEM 24 EXT 8 5VY 13414 00 GSKT STRAINER 3 9 5VY 15451 00 GSKT COVER1 3 ACM 10 5VY 15461 00 GSKT COVER2 3 CLUTCH 11 5VY 15456 00 GSKT 1...

Page 7: ...ve the hose attached to the cylinder head cover and the air cut off valve accompanying the hose 2 Remove the cap fitted to the hose remove the reed valve and plate from inside 3 Install the plate 5SL 1482L 70 in replacement of the cap Apply liquid gasket to the plate 4 Remove the cylinder head cover and the four collars fitted to the cover Install the PIN 93608 16M16 5 After removing the hose conn...

Page 8: ...les the punched alpha numeral 5VY to be visible The standard head cylinder gasket thickness is 0 40 mm and the cylinder gasket thickness is 0 20 mm No PART No PART NAME Q TY REMARKS 1 5VY 11181 70 GASKET HEADCYL 1 t 0 30 mm 2 5VY 11181 80 GASKET HEADCYL 1 t 0 35 mm 3 5VY 11351 70 GASKET CYL 1 t 0 10 mm 4 5VY 11351 80 GASKET CYL 1 t 0 15 mm REMOVE ...

Page 9: ...11 70 The standard valve timing is 105 for both intake and exhaust valves No PART No PART NAME Q TY REMARKS 1 5VY 12171 70 SHAFT CAM 1 1 2 5VY 12181 70 SHAFT CAM 2 1 Nominal Working angle Major Axis 286 8 5 286 33 8 288 8 5 288 31 8 No PART No PART NAME Q TY REMARKS 1 5VY 12113 70 SPRG 1 12 For 5VY 12171 70 2 5VY 12114 70 SPRG 2 8 For 5VY 12181 70 1 2 90105 07003 5VY 12176 00 ...

Page 10: ...nt is 105 for both intake and exhaust valves For valve adjustment use the oval holes in the standard cam sprocket No PART No PART NAME Q TY REMARKS 1 5VY 12171 80 SHAFT CAM 1 1 2 5VY 12181 80 SHAFT CAM 2 1 Nominal Working angle Major axis 288 7 9 288 32 9 288 7 8 288 30 8 USE THESE OVAL HOLES FOR TIMING ADJUSTMENT USE THESE OVAL HOLES FOR TIMING ADJUSTMENT ...

Page 11: ...INTAKE 2 8 Side of intake L 88 34 3 5VY 12121 70 VALVE EXT 8 No PART No PART NAME Q TY REMARKS 1 5VY 12111 00 VALVE INTAKE 4 2 5VY 12112 00 VALVE INTAKE 8 3 5VY 12121 00 VALVE EXHAUST 8 4 5NL 12116 00 SEAT VALVE SPRING 12 5 3GM 12126 00 SEAT VALVE SPRING 2 8 6 5VY 12113 00 SPRING VALVE INNER 12 7 5VY 12114 00 SPRING VALVE OUTER 8 8 5VY 12117 00 RETAINER VALVE SPRING 12 9 5VY 12127 00 RETAINER VALV...

Page 12: ... from the water passages After water has been added let the engine idle with the radiator cap removed and add water to fill the space formed in the passage by the escape of air Lastly tighten the cap No PART No PART NAME Q TY REMARKS 1 5VY 1240A 70 RADIATOR ASS Y 1 2 95817 06012 BOLT 1 3 90430 06014 GASKET 1 4 90480 15363 GROMMET 1 5 90387 0614M COLLAR 1 6 95827 06030 BOLT 1 7 90201 06071 WASHER 1...

Page 13: ...ed place Before installation apply a thin coat of grease to the threads of the funnel and plate For standard setting use funnel 5VY 14469 70 the shorter one Select the setting according to exhaust pipe specification rider s preference and track layout No PART No PART NAME Q TY REMARKS 5VY 14477 70 PLATE 2 5VY 14469 70 FUNNEL 1 4 L 27 mm 5VY 14469 90 FUNNEL 1 4 L 46 mm ...

Page 14: ...Clutch Boss Parts List The clutch spring has a 10 better load capacity than the standard one No PART No PART NAME Q TY REMARKS 1 5VY 16334 70 SPRING CLUTCH 6 2 5VY 16371 70 BOSS CLUTCH 1 INSTALL WITH THE MACHINED SIDE DOWN ...

Page 15: ... Use nine 9 5VY 16321 00 plates as friction plates 11 ACM Rotor Parts List No PART No PART NAME Q TY REMARKS 1 5SL 81450 70 ROTOR 1 1 2 2 2 90159 06009 5VY 16351 00 5VY 16325 00 5VY 16321 00 90179 20007 90208 20001 INSTALL STD PARTS DIRECTION OF ONE WAY CLUTCH ROTATION ...

Page 16: ...bolts M8 to 22 0 Nm and the other bolts M6 to 10 0 Nm 12 Engine Control Unit ECU Parts List CAUTION concerning the basic motorcycle The ECU kit cannot be used if the basic motorcycle conforms to the European specification and if the part number of the main harness is 5VY 82590 00 Use the harness from the kit A combination of harness 5VY 82590 10 intended for the USA and Australia and the ECU kit c...

Page 17: ...s connected When it is removed the ST specification becomes available A Setting Fuel Injection Changes that may be made to fuel injection CAUTION It is recommended that an A F measuring instrument should be used for this setting when checking the A F figures on the instrument At high revolutions in particular too lean a mixture may damage the engine The range of adjustment shown on the meter is 25...

Page 18: ...s a result of the initial to half throttle opening Jump out at the start and hesitation at half throttle opening may be solved by a leaner A F Make a change of 2 to 5 at a time while checking any resulting changes F4 Adjusts the volume of fuel injected at any engine speed at a throttle opening of 90 or more This mode constitutes the basic F5 to F9 data F5 to F9 Adjust the volume injected at indivi...

Page 19: ...rance of 10 FC Adjusts the ignition timing at a throttle opening of 90 or more and at an engine speed of 3000 rpm or more This range is apt to cause problems according to engine tuning In particular if the setting is on the side change degrees one by one while checking the result C Adjustment of the RAM Pressure Fuel Volume Correction FD This ECU is designed to correct the fuel injection volume in...

Page 20: ... value When confirmation is made FX_YY appears in the display YY indicates the applicable value and 0 the standard value For fuel volume correction is shown and for ignition timing correction the timing angle is shown To change the YY value press the SELECT or RESET buttons and change the numerical value To confirm the changed value and to transfer to another mode simultaneously press the SELECT a...

Page 21: ...Adjustment range 25 F5 Adjustment of fuel volume Throttle opening of 90 or more Engine speed of 9000 to 10000 rpm Adjustment range 25 F6 Adjustment of fuel amount Throttle opening of 90 or more Engine speed of 10000 to 11000 rpm Adjustment range 25 F7 Adjustment of fuel amount Throttle opening of 90 or more Engine speed of 11000 to 12000 rpm Adjustment range 25 F8 Adjustment of fuel amount Throttl...

Page 22: ...F1____ F1 FE FD F2 F1 FE e Check for Applicable Item F1 to FD Keep RESET SELECT simultaneously pressed F1___0 Current injection correction 0 appears in the lower area of LC Adjustable state of Code F1 at Ne 3000 rpm or less and Th 25 or less f Change in Adjustment Volume Each time SELECT is pressed the adjustment value is increased F1___1 F1___0 F1____ F1___1 2 3 Max 25 Refer to adjustment range F...

Page 23: ...be operated initialise adjustment value Switch is possible by pressing SELECT or RESET FE__88 88 appears in lower figure place in LC Initialisation mode for adjustment value Pressing SELECT or RESET alternately changes the mode either for checking the number of values to be operated or for initialisation k Initialisation of Changed Adjustment Values Initialisation mode being selected Keep RESET an...

Page 24: ...g system misaligned interrupted Possible 15 TPS broken short circuit Break short circuit between TPS and ECU Failure of TPS sensor Possible 20 Failure of intake pressure sensor or atmospheric pressure sensor Intake pressure sensor failure Failure of atmospheric pressure sensor Possible 21 Water temperature sensor break short circuit Break short circuit between water temp sensor and ECU Failure of ...

Page 25: ...ilure of fuel system power monitor voltage Wire broken short circuit between main relay and ECU Broken ECU voltage monitor wire Main relay failure Possible 46 Abnormal power for vehicle system Failure of charging system Failure in ACM or regulator Possible 47 Sub throttle sensor broken short circuit Broken short circuited line between sub throttle sensor and ECU Failure in sub throttle sensor Poss...

Page 26: ... throttle approx 95 degrees 02 Atmospheric pressure sensor Displays atmospheric pressure in Kpa Approx 101 Kpa at normal altitudes 03 Intake pressure sensor Displays intake vacuum in Kpa Displays atmospheric pressure when crankshaft is at rest Less than atmospheric pressure during starting motor cranking 05 Intake temp sensor Displays sensor detected temp in C 06 Water temp sensor Displays sensor ...

Page 27: ...t and taillight circuits are independent of one another If the headlight is broken the taillight will not go out For wiring see the WIRING DIAGRAM Code selected Item Description 36 Injector 1 Turning the engine switch off and on activates the injector 5 times 37 Injector 2 38 Injector 3 39 Injector 4 50 Main relay Turning the engine switch off and on activates main relay 5 times 53 EXUP Turning th...

Page 28: ...R LEAD ECU MAIN SWITCH SELECTOR SWITCH LEAD ENGINE KILL SWITCH LEAD OIL LEVEL GAUGE LEAD ACM LEAD STARTER MOTOR LEAD NEGATIVE BATTERY LEAD STARTING SAFETY RELAY EXTERNAL POWER CONNECTOR HEADLIGHT HARNESS ATMOSPHERIC PRESSURE SENSOR ENGINE STOP SWITCH MAIN FUSE STARTER RELAY HEADLIGHT CORD POSITIVE BATTERY LEAD FUSE BOX REMOVE FLASHER RELAY EXUP LEAD THROTTLE BODY LEAD TAILLIGHT UNIT PASS ON INSIDE...

Page 29: ...t No PART No PART NAME Q TY REMARKS 1 5VY 21707 70 CATCH TANK COMP 1 Capacity 630 cc 2 5EB 15373 70 HOSE 2 3 90450 25037 HOSE CLAMP ASS Y 6 4 5SL 11166 70 PIPE BREATHER 1 1 5 371 11167 01 PIPE BREATHER 1 1 6 4XV 21376 00 BAND 2 7 90464 08002 CLAMP 1 PASS UNDER TANK STAY ...

Page 30: ...for use in the standard shock absorber Specification No PART No PART NAME Q TY REMARKS 1 5VY 2117G 70 PROTECTOR 2 2 5SL 21472 70 COLLAR PROTECTOR LH 1 3 5SL 21477 70 COLLAR PROTECTOR RH 1 4 91317 10070 BOLT HEX SOCKET 2 5 90201 105R9 WASHER 2 No PART No PART NAME Q TY REMARKS 1 5VY 22212 70 SPRING 1 K 9 0 kgf mm KIT STD Free length 174 mm 174 mm Spring rate 9 0 kgf mm 8 5 kgf mm External colour Ye...

Page 31: ...he rebound spring keeps the fork from rebounding fully The spring rate is identified by the number of lines on its end Basic setting No PART No PART NAME Q TY REMARKS 1 5VY 23141 70 FR FORK SPRING 2 0 95 kgf mm 2 5PW 23118 00 SPACER 2 3 4XV 23142 00 SEAT SPRG UPPER 2 No PART No PART NAME Q TY REMARKS 1 5VY 23141 80 FR FORK SPRING 2 1 00 kgf mm 2 5PW 23118 00 SPACER 2 3 4XV 23142 00 SEAT SPRG UPPER...

Page 32: ... rotor 5 mm thick for improved durability when racing No PART No PART NAME Q TY REMARKS 1 5VY 2582T 70 DISK BRAKE Fr 1 t 5 0 2 5VY 25832 70 BRACKET DISK 1 3 5EB 2581M 70 PIN FLOATING 10 4 5EB 2581N 70 WASHER 10 5 93430 09052 CIRCLIP 10 6 90109 064G6 BOLT 6 5VY 23111 00 3XJ 23147 L0 3XC 23357 00 2 3 1 1 2 3 4 5 ...

Page 33: ... 29 20 Front Wheel Attachment Set This fixing assembly is intended for the TZ250 Marchesini wheel TZ250 MARCHESINI WHEEL ...

Page 34: ...ncluded in the rear arm fixing assembly or in the rear wheel fixing assembly No PART No PART NAME Q TY REMARKS 1 5VY 25388 70 PULLER 1 1 2 95317 20700 NUT 1 3 99009 32500 CIRCLIP 1 4 4FN 25322 70 INSERT SHAFT 1 5 90110 06142 BOLT 1 6 4XV 25379 70 BOLT PULLER 2 7 5VY 25389 70 0 PULLER 2 1 8 4XV 25381 70 AXLE WHEEL Rr 1 9 4XV 2580W 70 CALIPER ASSY 1 10 4XV 25911 70 PAD LINNING COMP 2 11 4XV 25379 70...

Page 35: ...he rear arm and puller 2 If a more competitive system is desired with a rear arm for endurance racing please contact the following company MG Competition ZAE LA FORET N 108 74130 CONTAMINE ARVE FRANCE TEL 33 0 450 255 996 FAX 33 0 450 255 998 E mail info mgcompetition fr or mgcompetition mgcompetition fr SCRAPE AWAY ...

Page 36: ...K 1 7 90149 06286 SCREW 3 8 90185 06122 NUT 3 9 4XV 25683 80 SPACER 1 10 4FN 25366 70 CLUTCH HUB 1 11 4XV 2539F 70 PLATE 1 12 91317 10025 BOLT 5 13 90185 10037 NUT 5 14 4XV 25376 80 COLLAR SPROCKET 1 15 4FN 25441 70 Rr SPROCKET 41T SIZE 520 16 5FL 93306 70 BEARING 1 4FN 25442 70 Rr SPROCKET 42T SIZE 520 4FN 25443 70 Rr SPROCKET 43T SIZE 520 4FN 25444 70 Rr SPROCKET 44T SIZE 520 4FN 25445 70 Rr SPR...

Page 37: ... 33 This fixing assembly is intended for Marchesini wheel 72186 for Yamaha Super Bike When using a different wheel refer to the hub size below chain line disk line DAMPER Marchesini 4031 ...

Page 38: ... 70 Rr SPROCKET 41T FOR STD WHEEL 520SIZE 6 4XV 25442 70 Rr SPROCKET 42T FOR STD WHEEL 520SIZE 7 4XV 25443 70 Rr SPROCKET 43T FOR STD WHEEL 520SIZE 8 4XV 25444 70 Rr SPROCKET 44T FOR STD WHEEL 520SIZE 9 4XV 25445 70 Rr SPROCKET 45T FOR STD WHEEL 520SIZE 10 4XV 25446 70 Rr SPROCKET 46T FOR STD WHEEL 520SIZE 11 4XV 25447 70 Rr SPROCKET 47T FOR STD WHEEL 520SIZE No PART No PART NAME Q TY REMARKS 1 5E...

Page 39: ... 35 This kit has an operation angle of 57 resulting in an improved racing operation The use of the 5SL 26243 71 with the tube guide included in the R6 kit allows an operating angle of 52 1 2 5 3 6 4 ...

Page 40: ... 70 ARM SHIFT 1 14 95824 06020 BOLT FLANGE 1 15 92017 06020 BOLT BUTTON HEAD 5 16 5VY 18115 70 ROD SHIFT 1 17 3TC 18116 00 JT ROD 1 1 18 95304 06700 NUT 1 19 3TC 18117 00 JT ROD 2 1 20 90170 06228 NUT 1 21 92017 06025 BOLT BUTTON HEAD 1 22 95607 06100 NUT U 2 23 5VY 27422 70 BRKT 2 1 24 5VY 27462 70 BRKT FOOTREST 2 1 25 5SL 27446 00 PLATE 2 1 26 5SL 2745A 71 COLLAR 4 27 5VY 2741L 70 BRKT 4 1 28 5E...

Page 41: ...the master cylinder with the rubber boot removed This footrest is located on the lower side 5 mm to the rear at the same height as that of the standard A change of 10 mm in height and of 5 mm to the rear of this location can be made for each step ...

Page 42: ...PART NAME Q TY REMARKS 1 5VY 28356 70 STAY 1 1 2 5VY 83519 70 BRACKET METER 1 3 90149 06298 SCREW 2 4 95707 06500 NUT 4 5 4XV 83513 00 DAMPER 7 6 5VY 28321 70 STAY 1 1 7 5VY 28322 70 STAY 2 1 8 95807 06040 BOLT 2 9 5PW 28386 00 HEAD 2 10 5PW 2177L 00 PLATE SPRING 2 11 90201 08008 WASHER 2 USE STD PARTS ...

Page 43: ...et includes an addition type of spindle in contrast with the assembly for the 03 R6 No PART No PART NAME Q TY REMARKS 1 5SL 92110 70 CUTTER INT 1 1 27 0 60 2 5SL 92110 80 CUTTER INT 2 1 27 0 90 3 5SL 92110 90 CUTTER INT 3 1 27 0 120 4 5SL 92120 70 CUTTER EXT 1 1 25 0 60 5 5SL 92120 80 CUTTER EXT 2 1 25 0 90 6 5SL 92120 90 CUTTER EXT 3 1 25 0 120 7 5SL 92101 70 SPINDLE 1 4 0 mm 8 5VY 92101 70 SPIND...

Page 44: ...3 Measure lMeasure the width of the valve seat a Non compliance with specification replace cylinder head Valve seat width 0 9 1 1 mm 0 0354 0 0433 in Limit 1 6 mm 0 06 in a Apply mechanic s blue Dykem b on the valve face b Install the valve in the cylinder head c Push the valve through the valve guide and on the valve seat to make a clear impression d Measure the width of the valve seat NOTE Where...

Page 45: ...alve seat are evenly polished then clean off all lapping compound NOTE For best lapping results lightly tap the valve seat while rotating the valve back and forth between your hands e Apply a fine lapping compound to the valve face and repeat the above steps f After every lapping cycle clean off all lapping compound from the valve face and valve seat g Apply mechanic s blue Dykem b on the valve fa...

Page 46: ...ber on the rear wall of the engine mount boss on the lower casing 3 Casing size number Crank journal size number 1 Bearing size number 5 Yellow 5VY 11416 40 4 Green 5VY 11416 30 3 Brown 5VY 11415 20 2 Black 5VY 11416 10 1 Blue 5VY 11416 00 0 White 5VY 11416 A0 CAUTION Before installing the bearing apply oil to its surface ...

Page 47: ... Selecting the connecting rod bearing Big end size number Crank pin size number Bearing size number 4 Green 5VY 11656 30 3 Brown 5VY 11656 20 2 Black 5VY 11656 10 1 Blue 5VY 11656 00 CAUTION Use the same weight management symbol alphabetical letter for all four connecting rods Install with mark Y on the left Apply oil Sign for selection of big end hole diameter Weight management sign ...

Page 48: ...nnecting bolts and to the connecting rod seating surface then install the connecting rods with aligning marks on the rods and caps in alignment with the individual crank pins Using the nut rotation method tighten the caps with an F type torque wrench to 19 6 1 96 Nm 2 0 0 2 kgf m and then retighten them in a rotation angle of 150 5 4 If the extension method is used adjust the bolt extension to 300...

Page 49: ...and nuts to secure the cylinder 3 Start installing the piston on the skirt side 4 Install the connecting rod on the crank Mating positions of the second ring installed with the T mark upward and the side rail downward Mating position of side rail upward Side rail upward Spacer Side rail downward Install the oil ring S e c u re a c le a ra n c e o f 3 m m o r m o re i n th e c li p m a ti n g p o s...

Page 50: ...iston without dismantling the crankcase insert the oil ring carefully A larger cylinder inclination may let the side rail come off and become wedged between the cylinders Take care not to damage the cylinder contact surface ...

Page 51: ... 196 Nm 2 0 kg m 2 Following the sequence tighten the bolts one by one and then retighten to a torque of 19 6 Nm 3 Following the tightening sequence retighten the bolts to an angle of 56 to 61 Reference tightening torque 35 0 Nm 3 5 kg m Bolt b 24 0 Nm 2 4 kg m Bolt c 12 Nm 1 2 kg m This number signifies the tightening order ...

Page 52: ...19 0 Nm 1 9 kgf m before tightening fully 2 Following the tightening sequence tighten to 67 0 Nm 6 8 kgf m 3 After tightening the nuts tighten the M6 bolts to 12 Nm 1 2 kgf m CAUTION The figures 1 to 10 indicate the tightening sequence Apply engine oil to the threads seating surfaces and washers ...

Page 53: ... 49 3 7 Camshaft installation Timing matching Timing matching mark Timing matching mark ...

Page 54: ... match the valve timing use the oval holes in the standard sprocket Rotation direction Ensure that the installed cam chain is not slack Up Side For installation push back the rod which actuates the guide and set the stopper as shown After installation slightly rotate the crank in the opposite direction to make the cam chain a little tight Push the tension device in this condition and the stopper w...

Page 55: ...5 Tighten f NUT on the crankcase bottom to the specified torque Then tighten the f NUT on the crankcase top to the specified torque 6 Tighten the a BOLT to the specified torque 7 Tighten the b BOLT to the specified torque Tightening torque of 45 Nm Tightening torque of 45 Nm Cylinder head as suspended Tightening torque of 50 Nm Tightening torque of 7 0 Nm Apply grease or engine oil to the thread b...

Page 56: ... Nm 3 Check that the axle head end is flush with the fork side end at D and if it is not make them flush applying external force by hand or a plastic headed hammer 4 Without preliminary tightening fully tighten the bolts in the sequence pinch bolt 4 pinch bolt 3 and pinch bolt 4 to 20 Nm CAUTION Pay attention to the direction of installation of the wheel assembly Apply grease to the seating surfac...

Page 57: ... sprocket installation 90105 06154 Bolt flange M6 1 0 15 2 1 5 0 2 1 Degrease thread Pump installation 90110 06026 Bolt flange M6 1 0 12 2 1 2 0 2 2 Thermostat assembly 90176 06065 Cap nut M6 1 0 10 2 1 0 0 2 2 Oil cooler installation 5EB 12822 00 Bolt union M20 1 5 63 3 6 3 0 3 1 Apply oil to thread and seating surface Drain bolt installation 90340 14132 Plug M14 1 5 43 4 4 3 0 4 1 Installation o...

Page 58: ...Close contact with seating surface 1 For crank turning Installation of plug to crankcase cover 1 5PX 15189 00 Plug M20 1 5 8 2 0 8 0 2 1 Oil return plug for main gallery 1 36Y 15189 00 Plug M16 1 5 8 2 0 8 0 2 3 Main gallery 2 4H7 15189 00 Plug M20 1 5 8 2 0 8 0 2 1 Oil return pipe 90110 06041 Bolt hexagonal socket head M6 1 0 10 2 1 0 0 2 2 Oil return plug 90340 12112 Plug straight screw M12 1 0 ...

Page 59: ... 1 25 45 2 4 5 0 2 1 Rear shock absorber relay arm 95607 10200 Nut M10 1 25 45 2 4 5 0 2 1 Rear shock absorber upper bracket 95607 14200 Nut M14 1 5 85 2 8 5 0 2 1 Handle crown outer tube 91314 08030 Bolt M8 1 25 22 2 2 2 0 2 2 Handlebar outer tube 91314 08030 Bolt M8 1 25 22 2 2 2 0 2 4 Handle crown steering shaft 90170 28419 Nut M28 1 0 110 2 10 0 0 2 1 Steering shaft ring nut lower 70179 30691 ...

Page 60: ... 56 Headlight cord wiring diagram ...

Page 61: ... 57 2004 YZF R1 Wiring Diagram ...

Page 62: ...YEC CO LTD 3622 8 Nishikaizuka Iwata Shizuoka 438 0026 Japan Tel 81 0538 37 4488 Fax 81 0538 37 6186 ...

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