2004 YAMAHA YZF-R1 check engine light

TABLE OF CONTENTSSAFETY INFORMATION ..................1-1
DESCRIPTION ..................................2-1
Left view ..........................................2-1
Right view ........................................2-2
Controls and instruments.................2-3
INSTRUMENT AND CONTROL
FUNCTIONS.......................................3-1
Immobilizer system .........................3-1
Main switch/steering lock ................3-2
Indicator and warning lights ............3-3
Multi-function meter unit .................3-8
Anti-theft alarm (optional) .............3-13
Handlebar switches ......................3-13
Clutch lever ...................................3-15
Shift pedal .....................................3-15
Brake lever ...................................3-15
Brake pedal ..................................3-16
Fuel tank cap ................................3-16
Fuel ...............................................3-17
Fuel tank breather/overflow
hose ..........................................3-18
Catalytic converter ........................3-18
Seats ............................................3-19
Helmet holders .............................3-20
Adjusting the front fork ..................3-20
Adjusting the shock absorber
assembly ...................................3-22
Luggage strap holders ..................3-24
EXUP system ...............................3-25Sidestand ..................................... 3-25
Ignition circuit cut-off system ........ 3-26
PRE-OPERATION CHECKS............. 4-1
Pre-operation check list .................. 4-2
OPERATION AND IMPORTANT
RIDING POINTS................................. 5-1
Starting the engine ......................... 5-1
Shifting ........................................... 5-2
Tips for reducing fuel
consumption ............................... 5-3
Engine break-in .............................. 5-3
Parking ........................................... 5-4
PERIODIC MAINTENANCE AND
MINOR REPAIR................................. 6-1
Owner’s tool kit ............................... 6-1
Periodic maintenance and
lubrication chart .......................... 6-2
Removing and installing the cowling
and panels .................................. 6-6
Checking the spark plugs ............... 6-8
Engine oil and oil filter cartridge ..... 6-9
Coolant ......................................... 6-12
Replacing the air filter element ..... 6-14
Adjusting the engine idling
speed ........................................ 6-16
Adjusting the throttle cable free
play ........................................... 6-16
Adjusting the valve clearance ...... 6-17Tires ............................................. 6-17
Cast wheels ................................. 6-20
Adjusting the clutch lever free
play ........................................... 6-20
Adjusting the rear brake light
switch ....................................... 6-21
Checking the front and rear brake
pads .......................................... 6-21
Checking the brake fluid level ...... 6-22
Changing the brake fluid .............. 6-23
Drive chain slack .......................... 6-23
Lubricating the drive chain ........... 6-24
Checking and lubricating the
cables ....................................... 6-25
Checking and lubricating the
throttle grip and cable ............... 6-25
Checking and lubricating the
brake and clutch levers ............ 6-26
Checking and lubricating the
sidestand .................................. 6-26
Lubricating the swingarm
pivots ........................................ 6-27
Checking the front fork ................. 6-27
Checking the steering .................. 6-28
Checking the wheel bearings ....... 6-28
Battery ......................................... 6-29
Replacing the fuses ..................... 6-30
Replacing a headlight bulb .......... 6-32
Tail/brake light ............................. 6-35
Replacing a turn signal light
bulb ........................................... 6-35U5VYE0E0.book Page 1 Friday, November 14, 2003 11:47 AM

SAFETY INFORMATION
1-3
1Loading
The total weight of the operator, pas-
senger, accessories and cargo must
not exceed the maximum load limit of
202 kg (445 lb). When loading within
this weight limit, keep the following in
mind:

Cargo and accessory weight
should be kept as low and close to
the motorcycle as possible. Make
sure to distribute the weight as
evenly as possible on both sides of
the motorcycle to minimize imbal-
ance or instability.


Shifting weights can create a sud-
den imbalance. Make sure that ac-
cessories and cargo are securely
attached to the motorcycle before
riding. Check accessory mounts
and cargo restraints frequently.


Never attach any large or heavy
items to the handlebar, front fork,
or front fender. These items, in-
cluding such cargo as sleeping
bags, duffel bags, or tents, can
create unstable handling or a slow
steering response.Accessories
Genuine Yamaha accessories have
been specifically designed for use on
this motorcycle. Since Yamaha cannot
test all other accessories that may be
available, you must personally be re-
sponsible for the proper selection, in-
stallation and use of non-Yamaha
accessories. Use extreme caution
when selecting and installing any ac-
cessories.
Keep the following guidelines in mind,
as well as those provided under “Load-
ing” when mounting accessories.

Never install accessories or carry
cargo that would impair the perfor-
mance of your motorcycle. Care-
fully inspect the accessory before
using it to make sure that it does
not in any way reduce ground
clearance or cornering clearance,
limit suspension travel, steering
travel or control operation, or ob-
scure lights or reflectors.
Accessories fitted to the handle-
bar or the front fork area can
create instability due to improper
weight distribution or aerody-
namic changes. If accessoriesare added to the handlebar or
front fork area, they must be as
lightweight as possible and
should be kept to a minimum.
Bulky or large accessories may
seriously affect the stability of
the motorcycle due to aerody-
namic effects. Wind may at-
tempt to lift the motorcycle, or
the motorcycle may become un-
stable in cross winds. These ac-
cessories may also cause
instability when passing or being
passed by large vehicles.
Certain accessories can dis-
place the operator from his or
her normal riding position. This
improper position limits the free-
dom of movement of the opera-
tor and may limit control ability,
therefore, such accessories are
not recommended.


Use caution when adding electri-
cal accessories. If electrical acces-
sories exceed the capacity of the
motorcycle’s electrical system an
electric failure could result, which
could cause a dangerous loss of
lights or engine power.
U5VYE0E0.book Page 3 Friday, November 14, 2003 11:47 AM

INSTRUMENT AND CONTROL FUNCTIONS
3-4
3
EAU11060
Neutral indicator light “”
This indicator light comes on when the
transmission is in the neutral position.
EAU11080
High beam indicator light “”
This indicator light comes on when the
high beam of the headlight is switched
on.
EAU11250
Oil level warning light “”
This warning light comes on when the
engine oil level is low.
The electrical circuit of the warning light
can be checked by turning the key to
“ON”.
If the warning light does not come on
for a few seconds, then go off, have a
Yamaha dealer check the electrical cir-
cuit.NOTE:

Even if the oil level is sufficient, the
warning light may flicker when
riding on a slope or during sudden
acceleration or deceleration, but
this is not a malfunction.


This model is also equipped with a
self-diagnosis device for the oil
level detection circuit. If the oil lev-
el detection circuit is defective, the
following cycle will be repeated un-
til the malfunction is corrected: The
oil level warning light will flash ten
times, then go off for 2.5 seconds.
If this occurs, have a Yamahadealer check the vehicle.
EAU11360
Fuel level warning light “”
This warning light comes on when the
fuel level drops below approximately
3.4 L (0.90 US gal) (0.75 Imp.gal).
When this occurs, refuel as soon as
possible.
The electrical circuit of the warning light
can be checked by turning the key to
“ON”.
If the warning light does not come on
for a few seconds, then go off, have a
Yamaha dealer check the electrical cir-
cuit.
NOTE:This model is also equipped with a self-
diagnosis device for the fuel level de-
tection circuit. If the fuel level detection
circuit is defective, the following cycle
will be repeated until the malfunction is
corrected: The fuel level warning light
will flash eight times, then go off for 2.5
seconds. If this occurs, have a Yamahadealer check the vehicle.
EAU11422
Coolant temperature warning light
“”
This warning light comes on when the
engine overheats. When this occurs,
stop the engine immediately and allow
the engine to cool.
The electrical circuit of the warning light
can be checked by turning the key to
“ON”.
If the warning light does not come on
for a few seconds, then go off, have a
Yamaha dealer check the electrical cir-
cuit.
U5VYE0E0.book Page 4 Friday, November 14, 2003 11:47 AM

INSTRUMENT AND CONTROL FUNCTIONS
3-7
3
EAU11530
Engine trouble warning light “”
This warning light comes on or flashes
when an electrical circuit monitoring the
engine is defective. When this occurs,
have a Yamaha dealer check the self-
diagnosis system. (See page 3-8 for an
explanation of the self-diagnosis de-
vice.)
The electrical circuit of the warning light
can be checked by turning the key to
“ON”. If the warning light does not come
on for a few seconds, then go off, have
a Yamaha dealer check the electrical
circuit.
EAU11571
Shift timing indicator light
This indicator light can be set to come
on and go off at the desired engine
speeds and is used to inform the rider
when it is time to shift to the next higher
gear.
The electrical circuit of the indicator
light can be checked by turning the key
to “ON”.
If the indicator light does not come on
for a few seconds, then go off, have a
Yamaha dealer check the electrical cir-cuit. (See page 3-8 for a detailed expla-
nation of the function of this indicator
light and on how to set it.)
EAU32990
Immobilizer system indicator light
“”
The electrical circuit of the indicator
light can be checked by turning the key
to “ON”.
If the indicator light does not come on
for a few seconds, then go off, have a
Yamaha dealer check the electrical cir-
cuit.
When the key is turned to “OFF” and 30
seconds have passed, the indicator
light will start flashing indicating the im-
mobilizer system is enabled. After 24
hours have passed, the indicator light
will stop flashing, however the immobi-
lizer system is still enabled.NOTE:This model is also equipped with a self-
diagnosis device for the immobilizer
system. If the immobilizer system is de-
fective, the indicator light will start flash-
ing a pattern and the
odometer/tripmeter will display a 2-digit
code when the key is turned to “ON”.When this occurs, have a Yamaha
dealer check the self-diagnosis system.
However, if the indicator light slowly
flashes five times, and then quickly
flashes two times repeatedly, error
code 52 will be displayed. This error
could be caused by signal interference.
If this occurs, try the following.
1. Use the code re-registering key to
start the engine.NOTE:Make sure there are no other immobi-
lizer keys close to the main switch, and
do not keep more than one immobilizer
key on the same key ring! Immobilizer
system keys may cause signal interfer-
ence, which may prevent the enginefrom starting.
2. If the engine starts, turn it off, and
try starting the engine with the
standard keys.
3. If one or both of the standard keys
do not start the engine, take the
vehicle, the code re-registering
key and both standard keys to a
Yamaha dealer and have the stan-
dard keys re-registered.
U5VYE0E0.book Page 7 Friday, November 14, 2003 11:47 AM

INSTRUMENT AND CONTROL FUNCTIONS
3-11
3 1. Use the code re-registering key to
start the engine.
NOTE:Make sure there are no other immobi-
lizer keys close to the main switch, and
do not keep more than one immobilizer
key on the same key ring! Immobilizer
system keys may cause signal interfer-
ence, which may prevent the enginefrom starting.
2. If the engine starts, turn it off and
try starting the engine with the
standard keys.
3. If one or both of the standard keys
do not start the engine, take the
vehicle, the code re-registering
key and both standard keys to a
Yamaha dealer and have the stan-
dard keys re-registered.
If the right display indicates any error
codes, note the code number, and then
have a Yamaha dealer check the vehi-
cle.
CAUTION:
ECA11590
If the display indicates an error
code, the vehicle should be checked
as soon as possible in order to avoidengine damage.
Display brightness and shift timing
indicator light control mode
This mode cycles through five control
functions, allowing you to make the fol-
lowing settings in the order listed be-
low.

Display brightness:
This function allows you to adjust
the brightness of the displays and
tachometer to suit the outside
lighting conditions.


Shift timing indicator light activity:
This function allows you to choose
whether or not the indicator light
should be activated and whether it
should flash or stay on when acti-
vated.


Shift timing indicator light activa-
tion:
This function allows you to select
the engine speed at which the indi-
cator light will be activated.


Shift timing indicator light deactiva-
tion:
This function allows you to select
the engine speed at which the indi-
cator light will be deactivated.


Shift timing indicator light bright-
ness:
This function allows you to adjust
the brightness of the indicator light
to suit your preference.
NOTE:

To make any settings in this mode,
you have to cycle through all of its
functions. However, if the key is
turned to “OFF” or the engine is
started before completing the pro-
cedure, only the settings made be-
fore the “SELECT” button was last
pushed will be applied.


In this mode, the right display
shows the current setting for each
function (except the shift timing in-dicator light activity function).
U5VYE0E0.book Page 11 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

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