2004 YAMAHA YZF-R1 fuel

PERIODIC MAINTENANCE AND MINOR REPAIR
6-15
6 6. Remove the air filter element.
7. Install a new air filter element into
the air filter case.
CAUTION:
ECA10480


Make sure that the air filter ele-
ment is properly seated in the
air filter case.


The engine should never be op-
erated without the air filter ele-
ment installed, otherwise the
piston(s) and/or cylinder(s) maybecome excessively worn.
8. Install the air filter case cover by in-
stalling the screws, and then install
the rubber cap.9. Place the fuel tank in its original
position, and then install the bolts.
WARNING
EWA12380


Before installing the fuel tank,
make sure that the fuel hoses
are not damaged. If any fuel
hose is damaged, do not start
the engine. Have a Yamaha
dealer replace the hose, other-
wise fuel may leak.


Make sure that the fuel hoses
are properly connected and
routed, and are not pinched.


Be sure to place the fuel tank
breather/overflow hose in itsoriginal position.10. Install the panels.
11. Install the rider seat.
1. Air filter element
1. Fuel tank breather/overflow hose
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-17
6
EAU21400
Adjusting the valve clearance The valve clearance changes with use,
resulting in improper air-fuel mixture
and/or engine noise. To prevent this
from occurring, the valve clearance
must be adjusted by a Yamaha dealer
at the intervals specified in the periodic
maintenance and lubrication chart.
EAU21771
Tires To maximize the performance, durabil-
ity, and safe operation of your motor-
cycle, note the following points
regarding the specified tires.
Tire air pressure
The tire air pressure should be checked
and, if necessary, adjusted before each
ride.
WARNING
EWA10500


The tire air pressure must be
checked and adjusted on cold
tires (i.e., when the temperature
of the tires equals the ambient
temperature).


The tire air pressure must be ad-
justed in accordance with the
riding speed and with the total
weight of rider, passenger, car-
go, and accessories approvedfor this model.
WARNING
EWA11020
Because loading has an enormous
impact on the handling, braking,
performance and safety characteris-
tics of your motorcycle, you should
keep the following precautions in
mind.
Tire air pressure (measured on cold
tires):
0–90 kg (0–198 lb):
Fr o nt :
250 kPa (36 psi) (2.50 kgf/cm²)
Rear:
290 kPa (42 psi) (2.90 kgf/cm²)
90–202 kg (198–445 lb):
Fr o nt :
250 kPa (36 psi) (2.50 kgf/cm²)
Rear:
290 kPa (42 psi) (2.90 kgf/cm²)
High-speed riding:
Fr o nt :
250 kPa (36 psi) (2.50 kgf/cm²)
Rear:
290 kPa (42 psi) (2.90 kgf/cm²)
Maximum load*:
202 kg (445 lb)
* Total weight of rider, passenger, car-
go and accessories
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-30
6charger will damage the battery.
If you do not have access to a
sealed-type (MF) battery charg-
er, have a Yamaha dealer
charge your battery.
EAU34052
Replacing the fuses The main fuse and the electronic fuel
injection fuse are located under the rid-
er seat. (See page 3-19.)
The fuse box, which contains the fuses
for the individual circuits, is located be-
hind the cowling shown.If a fuse is blown, replace it as follows.
NOTE:
Include steps 2–4 and 8–9 only for thefuses in the fuse box.
1. Turn the key to “OFF” and turn off
the electrical circuit in question.
2. Remove the quick fasteners by
pushing the center in with a screw-
driver, then pulling the fastener
out.
1. Main fuse
2. Electronic fuel injection spare fuse
3. Electronic fuel injection fuse
1. Cowling
chapter6 Page 30 Thursday, November 20, 2003 10:44 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-32
6
CAUTION:
ECA10640
Do not use a fuse of a higher amper-
age rating than recommended to
avoid causing extensive damage to
the electrical system and possibly afire.
6. Turn the key to “ON” and turn on
the electrical circuit in question to
check if the device operates.
7. If the fuse immediately blows
again, have a Yamaha dealer
check the electrical system.8. Place the cowling in its original po-
sition, and then install and tighten
the quick fastener screws.
NOTE:Make sure that the projections are in-serted into the slots.
9. Install the quick fasteners.NOTE:To install a quick fastener, push its pin
back so that it protrudes from the fas-
tener head, then insert the fastener and
push the protruding pin in until it is flushwith the fastener head.
EAU33900
Replacing a headlight bulb This model is equipped with quartz bulb
headlights. If a headlight bulb burns
out, replace it as follows.
To replace a high beam headlight
bulb
1. Disconnect the headlight coupler,
and then remove the bulb cover.
Specified fuses:
Main fuse:
50.0 A
Backup fuse:
10.0 A
Ignition fuse:
15.0 A
Headlight fuse:
25.0 A
Signaling system fuse:
10.0 A
Turn signal light fuse:
10.0 A
Radiator fan fuse:
15.0 Ax 2
Electronic fuel injection fuse:
15.0 A
1. Slot
2. Projection
1. High beam headlight bulb
2. Low beam headlight bulb
chapter6 Page 32 Thursday, November 20, 2003 10:44 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-41
6
CAUTION:
ECA11070
Do not apply the brake after the
wheel has been removed together
with the brake disc, otherwise thebrake pads will be forced shut.
EAU25661
To install the rear wheel
1. Install the wheel and the brake cal-
iper bracket by inserting the wheel
axle from the left-hand side.NOTE:

Be sure to insert the retainer on the
brake caliper bracket into the slot
in the swingarm.


Make sure that there is enough
space between the brake pads be-fore installing the wheel.
2. Install the drive chain onto the rear
sprocket.
3. Install the axle nut, and then lower
the rear wheel so that it is on the
ground.
4. Adjust the drive chain slack. (See
page 6-23.)
5. Tighten the axle nut to the speci-
fied torque.
EAU25870
Troubleshooting Although Yamaha motorcycles receive
a thorough inspection before shipment
from the factory, trouble may occur dur-
ing operation. Any problem in the fuel,
compression, or ignition systems, for
example, can cause poor starting and
loss of power.
The following troubleshooting charts
represent quick and easy procedures
for checking these vital systems your-
self. However, should your motorcycle
require any repair, take it to a Yamaha
dealer, whose skilled technicians have
the necessary tools, experience, and
know-how to service the motorcycle
properly.
Use only genuine Yamaha replace-
ment parts. Imitation parts may look like
Yamaha parts, but they are often inferi-
or, have a shorter service life and can
lead to expensive repair bills.
1. Wheel axle
1. Retainer
2. Slot
Tightening torque:
Axle nut:
150 Nm (15.0 m·kgf, 108 ft·lbf)
U5VYE0E0.book Page 41 Friday, November 14, 2003 11:47 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-42
6
EAU25911
Troubleshooting charts Starting problems or poor engine performance
WARNING
EWA10840
Keep away open flames and do not smoke while checking or working on the fuel system.
Check the fuel level in
the fuel tank.1. Fuel
There is enough fuel.
There is no fuel.
Check the compression.
Supply fuel.
The engine does not start.
Check the compression.
Operate the electric starter.2. Compression
There is compression.
There is no compression.
Check the ignition.
Have a Yamaha dealer
check the vehicle.
Remove the spark plugs
and check the electrodes.3. Ignition
Wipe off with a dry cloth and correct the
spark plug gaps, or replace the spark plugs.
Have a Yamaha dealer check the vehicle.
The engine does not start.
Have a Yamaha dealer
check the vehicle.
The engine does not start.
Check the battery.
Operate the electric starter.4. Battery
The engine turns over
quickly.
The engine turns over
slowly.
The battery is good.Check the battery lead connections,
and charge the battery if necessary.
DryWet
Open the throttle halfway and operate
the electric starter.
U5VYE0E0.book Page 42 Friday, November 14, 2003 11:47 AM

MOTORCYCLE CARE AND STORAGE
7-1
7
EAU26020
Care While the open design of a motorcycle
reveals the attractiveness of the tech-
nology, it also makes it more vulnera-
ble. Rust and corrosion can develop
even if high-quality components are
used. A rusty exhaust pipe may go un-
noticed on a car, however, it detracts
from the overall appearance of a motor-
cycle. Frequent and proper care does
not only comply with the terms of the
warranty, but it will also keep your
motorcycle looking good, extend its life
and optimize its performance.
Before cleaning
1. Cover the muffler outlet with a
plastic bag after the engine has
cooled down.
2. Make sure that all caps and covers
as well as all electrical couplers
and connectors, including the
spark plug caps, are tightly in-
stalled.
3. Remove extremely stubborn dirt,
like oil burnt onto the crankcase,
with a degreasing agent and a
brush, but never apply such prod-ucts onto seals, gaskets, sprock-
ets, the drive chain and wheel
axles. Always rinse the dirt and de-
greaser off with water.
Cleaning
CAUTION:
ECA11140


Avoid using strong acidic wheel
cleaners, especially on spoked
wheels. If such products are
used on hard-to-remove dirt, do
not leave the cleaner on the af-
fected area any longer than in-
structed. Also, thoroughly rinse
the area off with water, immedi-
ately dry it, and then apply a cor-
rosion protection spray.


Improper cleaning can damage
windshields, cowlings, panels,
other plastic parts, and the muf-
fler. Use only a soft, clean cloth
or sponge with mild detergent
and water to clean plastic. How-
ever, if the muffler cannot be
thoroughly cleaned with mild
detergent, alkaline products
and a soft brush may be used.


Do not use any harsh chemical
products on plastic parts or the
muffler. Be sure to avoid using
cloths or sponges which have
been in contact with strong or
abrasive cleaning products, sol-
vent or thinner, fuel (gasoline),
rust removers or inhibitors,
brake fluid, antifreeze or electro-
lyte.


Do not use high-pressure wash-
ers or steam-jet cleaners since
they cause water seepage and
deterioration in the following ar-
eas: seals (of wheel and swing-
arm bearings, fork and brakes),
storage compartments, electric
components (couplers, connec-
tors, instruments, switches and
lights), breather hoses and
vents.


For motorcycles equipped with
a windshield: Do not use strong
cleaners or hard sponges as
they will cause dulling or
scratching. Some cleaning com-
pounds for plastic may leave
scratches on the windshield.
Test the product on a small hid-
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MOTORCYCLE CARE AND STORAGE
7-3
74. To prevent corrosion, it is recom-
mended to apply a corrosion pro-
tection spray on all metal,
including chrome- and nickel-plat-
ed, surfaces.
5. Use spray oil as a universal clean-
er to remove any remaining dirt.
6. Touch up minor paint damage
caused by stones, etc.
7. Wax all painted surfaces.
8. Let the motorcycle dry completely
before storing or covering it.
WARNING
EWA11130


Make sure that there is no oil or
wax on the brakes or tires.


If necessary, clean the brake
discs and brake linings with a
regular brake disc cleaner or ac-
etone, and wash the tires with
warm water and a mild deter-
gent. Before riding at higher
speeds, test the motorcycle’s
braking performance and cor-nering behavior.
CAUTION:
ECA10800


Apply spray oil and wax spar-
ingly and make sure to wipe off
any excess.


Never apply oil or wax to any
rubber and plastic parts, but
treat them with a suitable care
product.


Avoid using abrasive polishing
compounds as they will wearaway the paint.
NOTE:Consult a Yamaha dealer for advice onwhat products to use.
EAU26201
Storage Short-term
Always store your motorcycle in a cool,
dry place and, if necessary, protect it
against dust with a porous cover.CAUTION:
ECA10810


Storing the motorcycle in a
poorly ventilated room or cover-
ing it with a tarp, while it is still
wet, will allow water and humid-
ity to seep in and cause rust.


To prevent corrosion, avoid
damp cellars, stables (because
of the presence of ammonia)
and areas where strong chemi-cals are stored.
Long-term
Before storing your motorcycle for sev-
eral months:
1. Follow all the instructions in the
“Care” section of this chapter.
2. Fill up the fuel tank and add fuel
stabilizer (if available) to prevent
the fuel tank from rusting and the
fuel from deteriorating.
U5VYE0E0.book Page 3 Friday, November 14, 2003 11:47 AM