YEC '04 YZF-R1 Handbuch
’04 YZF-R1
KIT MANUAL
The Performance Edge
for top-ranking riders
2004 YZF-R1 Kit Manual
Please note :
•It should be understood that these kit parts are not covered by warranty.
•The manufacturer does not assume any responsibility for problems caused by
these parts.
•These kit 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 maintenance.
CONTENTS
1 Standard Specifications ...................................................................................1
2 Kit Parts .............................................................................................................2
2-1 Basic Kit Set Contents..............................................................................2
2-2 Engine Parts ..............................................................................................2
1. Maintenance set (5VY-MAINT-70).......................................................2
2. Spark Plugs ........................................................................................3
3. AIS Plug Set (5VY-A4890-70) .............................................................3
4. Gaskets...............................................................................................4
5. High-lift Camshaft, Valve Spring ........................................................5
6. Standard-lift Camshafts ....................................................................6
7. Flat Valve Set (5VY-A2100-70)............................................................7
8. Sub-radiator Set (5VY-A240A-70) ......................................................8
9. Funnel Set (5VY-A4460-70) ...............................................................9
10. Clutch Spring, Clutch 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 .................30
22. Sprocket, Sprocket Nut....................................................................34
23. Throttle Set (5VY-C6300-70).............................................................34
24. Footrest Set (5VY-C7400-70)............................................................36
25. Front Stay Set (5VY-C8350-70) ........................................................38
2-4 Other.........................................................................................................39
26. Valve Seat Cutter Set........................................................................39
3 Installation Precautions ..................................................................................40
3-1 Checking the Valve Seats.......................................................................40
3-2 Selecting the crankshaft bearing...........................................................42
3-3 Selecting the connecting rod bearing...................................................43
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
- 1 -
1 Standard Specifications
Item Standard Basic Kit
Displacement
998 cm
3
Bore/stroke
Primary reduction gear ratio
77,0 mm/53,6 mm
65/43 (1.512)
Compression ratio
Surface honing
12.4:1
-
13.3:1
0,45 mm
Squish height
0,75 mm 0,60 mm
Camshaft INT
Nominal
Major axis
5VY-00
292° – 7.6
32,9 mm
5VY-70
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 (1.762)
35/23 (1.522)
30/22 (1.364)
33/26 (1.269)
Clutch Wet type, multiple disc
Ignition timing
DC-CDI
- 2 -
2KitParts
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
- 3 -
2. Spark Plugs
Parts List
Set No. : 5FL-R045Q-70 (R0045Q-10, 4 plugs)
CAUTION :
Since these spark plugs have a copper gasket, caution is needed during
installation on the following points.
1. The tightening torque is 1.0 – 1.2 kg·m.
2. When not checking the torque, tighten by rotating through only 30° after
manual tightening in the case of new plugs. When reusing plugs, tighten by
rotating through 15°.
3.
AIS Plug Set (5VY-A4890-70)
This plug set is used when the AIS (Air Induction System), an exhaust gas purifying
system, is removed.
Parts List
Installation
1. Remove 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 connected to the air filter casing form the air cut-off
assembly, insert the PLUG (90336-10020) onto the side of the air filter casing to
close the opening.
No. PART No. PART NAME Q’TY REMARKS
15
FL-94700-70 PLUG, SPARK 1 NGK R0045Q-10
No. PART No. PART NAME Q’TY REMARKS
1 5SL-1482L-70 PLATE 2
* 2 93608-16M16 PIN 4
* 3 93306-10020 PLUG 1
Reused (15°)
New gasket
(30°)
- 4 -
4. Gaskets
Parts List
These parts are used to adjust the squish height and compression ratio.
They should be installed in the direction, which enables 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.
1t=0,30mm
2 5VY-11181-80
GASKET, HEADCYL.
1t=0,35mm
3 5VY-11351-70
GASKET, CYL.
1t=0,10mm
4 5VY-11351-80
GASKET, CYL.
1t=0,15mm
REMOVE
- 5 -
5. High-lift Camshaft, Valve Spring
High-lift specification
When using these camshafts, the valve springs should also be those in the kit.
Specification
Valve spring set (5VY-A2111-70)
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
- 6 -
To adjust the valve timing, use the oval holes of the standard cam sprocket.
6. Standard-lift Camshafts
Parts List
Specification
The standard valve adjustment 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.
Dieses Handbuch passt für folgende Modelle
1
Inhaltsverzeichnis
Beliebte Motorrad Handbücher anderer Marken
MOTO GUZZI
MOTO GUZZI QUOTA 1100 ES Bedienungsanleitung
APRILIA
APRILIA ETV MILLE CAPONORD - PART1 02-2001 Bedienungsanleitung
Yamaha
Yamaha 2006 YZF-R1V Bedienungsanleitung
KTM
KTM Freeride E-XC 2021 Bedienungsanleitung
Fantic
Fantic Enduro 125 Bedienungsanleitung
Ducati
Ducati Supersport 750 desmodue Bedienungsanleitung
