2004 YAMAHA YZF-R1 check engine

INSTRUMENT AND CONTROL FUNCTIONS
3-26
3
EAU15311
Ignition circuit cut-off system The ignition circuit cut-off system (com-
prising the sidestand switch, clutch
switch and neutral switch) has the fol-
lowing functions.

It prevents starting when the trans-
mission is in gear and the side-
stand is up, but the clutch lever is
not pulled.


It prevents starting when the trans-
mission is in gear and the clutch le-
ver is pulled, but the sidestand is
still down.


It cuts the running engine when the
transmission is in gear and the sid-
estand is moved down.
Periodically check the operation of the
ignition circuit cut-off system according
to the following procedure.WARNING
EWA10250
If a malfunction is noted, have a
Yamaha dealer check the system be-fore riding.U5VYE0E0.book Page 26 Friday, November 14, 2003 11:47 AM

INSTRUMENT AND CONTROL FUNCTIONS
3-27
3
With the engine turned off:
1. Move the sidestand down.
2. Make sure that the engine stop switch is turned on.
3. Turn the key on.
4. Shift the transmission into the neutral position.
5. Push the start switch.
Does the engine start?
With the engine still running:
6. Move the sidestand up.
7. Keep the clutch lever pulled.
8. Shift the transmission into gear.
9. Move the sidestand down.
Does the engine stall?
After the engine has stalled:
10. Move the sidestand up.
11. Keep the clutch lever pulled.
12. Push the start switch.
Does the engine start?
The system is OK. The motorcycle can be ridden.
This check is most reliable if performed with
a warmed-up engine.The neutral switch may be defective.
The motorcycle should not be ridden until
checked by a Yamaha dealer.
The sidestand switch may be defective.
The motorcycle should not be ridden until
checked by a Yamaha dealer.
The clutch switch may be defective.
The motorcycle should not be ridden until
checked by a Yamaha dealer.
YES NO YES NO YES NONOTE:
U5VYE0E0.book Page 27 Friday, November 14, 2003 11:47 AM

PRE-OPERATION CHECKS
4-2
4
EAU15602
Pre-operation check list
ITEM CHECKS PAGE
FuelCheck fuel level in fuel tank.
Refuel if necessary.
Check fuel line for leakage.3-17
Engine oilCheck oil level in engine.
If necessary, add recommended oil to specified level.
Check vehicle for oil leakage.6-9
CoolantCheck coolant level in reservoir.
If necessary, add recommended coolant to specified level.
Check cooling system for leakage.6-12
Front brakeCheck operation.
If soft or spongy, have Yamaha dealer bleed hydraulic system.
Check brake pads for wear.
Replace if necessary.
Check fluid level in reservoir.
If necessary, add recommended brake fluid to specified level.
Check hydraulic system for leakage.6-21, 6-22
Rear brakeCheck operation.
If soft or spongy, have Yamaha dealer bleed hydraulic system.
Check brake pads for wear.
Replace if necessary.
Check fluid level in reservoir.
If necessary, add recommended brake fluid to specified level.
Check hydraulic system for leakage.6-21, 6-22
ClutchCheck operation.
Lubricate cable if necessary.
Check lever free play.
Adjust if necessary.6-20
U5VYE0E0.book Page 2 Friday, November 14, 2003 11:47 AM

OPERATION AND IMPORTANT RIDING POINTS
5-1
5
EAU15950
WARNING
EWA10270


Become thoroughly familiar
with all operating controls and
their functions before riding.
Consult a Yamaha dealer re-
garding any control or function
that you do not thoroughly un-
derstand.


Never start the engine or oper-
ate it in a closed area for any
length of time. Exhaust fumes
are poisonous, and inhaling
them can cause loss of con-
sciousness and death within a
short time. Always make sure
that there is adequate ventila-
tion.


Before starting out, make sure
that the sidestand is up. If the
sidestand is not raised com-
pletely, it could contact the
ground and distract the opera-
tor, resulting in a possible lossof control.
EAU33010
Starting the engine In order for the ignition circuit cut-off
system to enable starting, one of the
following conditions must be met:

The transmission is in the neutral
position.


The transmission is in gear with
the clutch lever pulled and the sid-
estand up.WARNING
EWA10290


Before starting the engine,
check the function of the igni-
tion circuit cut-off system ac-
cording to the procedure
described on page 3-26.


Never ride with the sidestanddown.
1. Turn the key to “ON” and make
sure that the engine stop switch is
set to “”.
CAUTION:
ECA11730
The following warning lights and in-
dicator light should come on for a
few seconds, then go off.

Oil level warning light


Fuel level warning light


Coolant temperature warning
light


Shift timing indicator light


Engine trouble warning light


Immobilizer system indicator
light
If a warning or indicator light does
not go off, see page 3-3 for the corre-
sponding warning and indicator
light circuit check.
2. Shift the transmission into the neu-
tral position.NOTE:When the transmission is in the neutral
position, the neutral indicator light
should be on, otherwise have a
Yamaha dealer check the electrical cir-cuit.
3. Start the engine by pushing the
start switch.NOTE:If the engine fails to start, release the
start switch, wait a few seconds, and
then try again. Each starting attempt
should be as short as possible to pre-
U5VYE0E0.book Page 1 Friday, November 14, 2003 11:47 AM

OPERATION AND IMPORTANT RIDING POINTS
5-4
5
CAUTION:
ECA10301
After 1000 km (600 mi) of operation,
the engine oil must be changed and
the oil filter cartridge or element re-placed.
1600 km (1000 mi) and beyond
The vehicle can now be operated nor-
mally.CAUTION:
ECA10310


Keep the engine speed out of
the tachometer red zone.


If any engine trouble should oc-
cur during the engine break-in
period, immediately have a
Yamaha dealer check the vehi-cle.
EAU17211
Parking When parking, stop the engine, and
then remove the key from the main
switch.
WARNING
EWA10310


Since the engine and exhaust
system can become very hot,
park in a place where pedestri-
ans or children are not likely to
touch them.


Do not park on a slope or on soft
ground, otherwise the vehiclemay overturn.
CAUTION:
ECA10380
Never park in an area where there
are fire hazards such as grass orother flammable materials.
U5VYE0E0.book Page 4 Friday, November 14, 2003 11:47 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-3
6
10*TiresCheck tread depth and for damage.
Replace if necessary.
Check air pressure.
Correct if necessary.√√√√ √
11*Wheel bearingsCheck bearing for looseness or damage.√√√√
12*SwingarmCheck operation and for excessive play.√√√√
Lubricate with lithium-soap-based grease. Every 50000 km
13 Drive chainCheck chain slack.
Make sure that the rear wheel is properly aligned.
Clean and lubricate. Every 800 km and after washing the motorcycle or
riding in the rain
14*Steering bearingsCheck bearing play and steering for roughness.√√√√√
Lubricate with lithium-soap-based grease. Every 20000 km
15*Steering damperCheck operation and for oil leakage.√√√√
16*Chassis fastenersMake sure that all nuts, bolts and screws are properly
tightened.√√√√ √
17 SidestandCheck operation.
Lubricate.√√√√ √
18*Sidestand switchCheck operation.√√√√√ √
19*Front forkCheck operation and for oil leakage.√√√√
20*Shock absorber assem-
blyCheck operation and shock absorber for oil leakage.√√√√
21*Rear suspension relay
arm and connecting
arm pivoting pointsCheck operation.√√√√
22*Electronic fuel injectionAdjust engine idling speed and synchronization.√√√√√ √ NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (× 1000 km)
ANNUAL
CHECK
1 10203040
U5VYE0E0.book Page 3 Friday, November 14, 2003 11:47 AM

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

PERIODIC MAINTENANCE AND MINOR REPAIR
6-8
6To install the panel
1. Place the panel in its original posi-
tion, and then install the screw.
2. Install the rider seat.
EAU19651
Checking the spark plugs The spark plugs are important engine
components, which should be checked
periodically, preferably by a Yamaha
dealer. Since heat and deposits will
cause any spark plug to slowly erode,
they should be removed and checked
in accordance with the periodic mainte-
nance and lubrication chart. In addition,
the condition of the spark plugs can re-
veal the condition of the engine.
The porcelain insulator around the cen-
ter electrode of each spark plug should
be a medium-to-light tan (the ideal color
when the vehicle is ridden normally),
and all spark plugs installed in the en-
gine should have the same color. If any
spark plug shows a distinctly different
color, the engine could be defective. Do
not attempt to diagnose such problems
yourself. Instead, have a Yamaha deal-
er check the vehicle.
If a spark plug shows signs of electrode
erosion and excessive carbon or other
deposits, it should be replaced.Before installing a spark plug, the spark
plug gap should be measured with a
wire thickness gauge and, if necessary,
adjusted to specification.
Clean the surface of the spark plug
gasket and its mating surface, and then
wipe off any grime from the spark plug
threads.Specified spark plug:
NGK/CR9EK
1. Spark plug gapSpark plug gap:
0.6–0.7 mm (0.024–0.028 in)
Tightening torque:
Spark plug:
12.5 Nm (1.25 m·kgf, 9 ft·lbf)
U5VYE0E0.book Page 8 Friday, November 14, 2003 11:47 AM