’04 YZF-R1 KIT MANUAL The Performance Edge for top-ranking riders
004 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.
CONTENTS 1 2 Standard Specifications ...................................................................................1 Kit Parts .............................................................................................................2 2-1 Basic Kit Set Contents..............................................................................2 2-2 Engine Parts ..............................................................................................2 1. Maintenance set (5VY-MAINT-70)................
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 ........................
1 Standard Specifications Item Standard Displacement 998 cm3 Basic Kit Bore/stroke 77,0 mm/53,6 mm Primary reduction gear ratio 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.
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 * 1 5VY-11181-00 GSKT.
2. Spark Plugs Parts List No. PART No. PART NAME Q’TY 1 5 FL-94700-70 PLUG, SPARK 1 REMARKS NGK R0045Q-10 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°.
REMOVE 4. Gaskets Parts List 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 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.
5. High-lift Camshaft, Valve Spring High-lift specification No. PART No. PART NAME Q’TY 1 5VY-12171-70 SHAFT, CAM 1 1 2 5VY-12181-70 SHAFT, CAM 2 1 REMARKS 90105-07003 5VY-12176-00 1 2 When using these camshafts, the valve springs should also be those in the kit. Specification Nominal Working angle Major Axis 286-8.5 286 33.8 288-8.5 288 31.8 Valve spring set (5VY-A2111-70) No. PART No. PART NAME Q’TY REMARKS 1 5VY-12113-70 SPRG.
To adjust the valve timing, use the oval holes of the standard cam sprocket. USE THESE OVAL HOLES FOR TIMING ADJUSTMENT. 6. Standard-lift Camshafts Parts List No. PART No. PART NAME Q’TY 1 5VY-12171-80 SHAFT, CAM 1 1 2 5VY-12181-80 SHAFT, CAM 2 1 REMARKS Specification Nominal Working angle Major axis 288-7.9 288 32.9 288-7.8 288 30.8 The standard valve adjustment is 105° for both intake and exhaust valves. For valve adjustment, use the oval holes in the standard cam sprocket.
7. Flat Valve Set (5VY-A2100-70) Parts List No. PART No. PART NAME Q’TY REMARKS 1 5VY-12111-70 VALVE, INTAKE 4 Centre of intake (L=87.16) 2 5VY-12112-70 VALVE, INTAKE 2 8 Side of intake (L=88.34) 3 5VY-12121-70 VALVE, EXT. 8 These valves are used to improve the compression ratio (about 0.2) by making their shape on the compression chamber side flatter than in the case of standard valves. They are made of steel and have the same weight as the standard ones.
8. Sub-radiator Set (5VY-A240A-70) Parts List No. PART No.
9. Funnel Set (5VY-A4460-70) Parts List 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 CAUTION : • The air cleaner case is kept fixed by the standard funnel. Remove this standard funnel and install the plate in its destined 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).
INSTALL WITH THE MACHINED SIDE DOWN. 10. Clutch Spring, Clutch Boss Parts List No. PART No. PART NAME Q’TY 1 5VY-16334-70 SPRING, CLUTCH 6 2 5VY-16371-70 BOSS, CLUTCH 1 REMARKS The clutch spring has a 10% better load capacity than the standard one.
The clutch boss has been surface-treated for improved durability. Use nine (9) 5VY-16321-00 plates as friction plates. 5VY-16351-00 90159-06009 1 5VY-16325-00 5VY-16321-00 2 2 90179-20007 90208-20001 11. ACM Rotor Parts List No. PART No.
This rotor is narrower than the standard rotor, aiming at a reduced inertia mass and frictional load. For the stator coil, use standard one. CAUTION : • The rotor and starter clutch are integrated. Use a standard starter clutch. • After the installation of the starter clutch, check for direction of rotation. • To install the stator coil-integrated cover, tighten the three (3) bolts (M8) to 22.0 Nm and the other bolts (M6) to 10.0 Nm. AFTER TIGHTENING THE 3 M8 BOLTS TO 22 Nm, TIGHTEN THE OTHER (M6) BOLTS.
NOTE on meter display: Connection of the ECU kit allows the standard meter to switch to the kit mode. STD : Clock Kit : Max. Water Temp. Retains Max. Temp. uring Run STD : Water Temp. Kit : No Display STD : ODO/TRIP Etc. Kit : Applicable Value Adjusting Mode STD : Speed Kit : Water Temp. Air Temp. (Select) Change of basic data Use of the kit harness makes it possible for basic data to be selected for SB (Super Bike) specification and ST (Stock Sports) specification.
THE INJECTION VOLUME F5 TO F9 IS ADJUSTED IN THE SAME WAY AS FOR F4. F4 F5 F6 F7 F8 F9 THROTTLE OPENING (%) 90 F3 25 F2 F1 0 9000 10000 11000 12000 13000 3000 ENGINE SPEED (rpm) RANGE OF ADJUSTMENT OF THE VOLUME OF INJECTION F1 TO F9 F0: Transfer to the adjustment mode is shown in the display area at the bottom RHS of the meter. F1: This mode helps to stabilize idle running. Too rich an A/F may foul the spark plug.
B. Ignition Timing Correction CAUTION : This function corrects the gaps for the optimum ignition timing according to the difference of the characteristics of the fuel used. Ignition timing must not be set at too early a (plus side) timing since it may cause problems. If no difference is felt as a result of correction, the ignition timing should be set on the slower side.
Procedure (fuel adjustment, ignition timing correction, and adjustment of RAM-pressure fuel correction volume) 1. 2. 3. 4. 5. D. Transfer to F0 mode Keeping both the “SELECT” and “RESET” buttons pressed simultaneously, turn on the main switch. “F0 ” appears in the display area at the bottom RHS of the meter. Transfer to the ECU applicable mode Keeping both the SELECT and RESET buttons pressed simultaneously. “F1” appears in the display.
Initialization (Bring all settings to “0”.) Press the “RESET” or “SELECT” button with “FE_YY” displayed. “FE_88” will appear. While checking this display, simultaneously keep both the “RESET” and “SELECT” buttons pressed. “FE_ 0” will be displayed and this completes initialisation. Turn off the main switch to end. • While each applicable value is being changed, the value immediately preceding is memorised in the ECU, even with the main switch off.
Operation Meter display Significance a Mode Transfer Keep "RESET" + "SELECT" simultaneously pressed and turn on "MAIN SWITCH".
Item Operation Meter display Significance (Items and their operating procedures are the same as [FE___*] Number of changes in adjustment values for F1 to FD appears in lower figure place in LC: Mode for checking the number of adjustment values to be operated. Holding "RESET" and "SELECT" simultaneously pressed allows transfer to Select ECU applicable item.
Self-diagnosis Function (1) Function This function detects a failure in the sensor and the actuator and alerts the user to the occurrence of failure by lighting up a pilot light on meter / displaying a failure code and simultaneously launching the evacuation procedure.
Failure code Item Major cause of failure 35 Ignition failure of #3 cylinder • Broken line between ignition coil and ECU • Failure in ignition coil interior Possible 36 Ignition failure of #4 cylinder • Broken line between ignition coil and ECU • Failure in ignition coil interior Possible 41 Overturn sensor (broken/short circuit) • Wire broken/short circuit between overturn sensor and ECU • Overturn sensor failure Possible 43 Failure of fuel system power (monitor voltage) • Wire broken/short
Diagnosis Function (Status Checking Function) (1) (2) (3) Function To help users with troubleshooting and maintenance, sensor output display and actuator operation are made possible without the use of special tools or measuring instruments. Procedure • Transfer to diagnostic mode as follows: • Hold down "RESET" and "SELECT" buttons on meter and turn on the main switch. Continue holding the buttons down, until "F0" appears on meter.
Code selected Item Description 36 Injector #1 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 the engine switch off and on activates EXUP motor from fully open to fully closed throttle. 56 Sub-throttle • Turning the engine switch off and on activates the sub-throttle motor from fully open to fully closed throttle. 60 No function 61 No function 62 No function 70 Management No.
WIRING DIAGRAM ENGINE KILL SWITCH LEAD OIL LEVEL GAUGE LEAD ACM LEAD STARTER MOTOR LEAD NEGATIVE BATTERY LEAD FUEL PUMP LEAD ENGINE GROUND LEAD CRANKSHAFT SENSOR LEAD SPEED SENSOR LEAD HANDLEBAR SWITCH (RIGHT) HEADLIGHT HARNESS CONNECTOR HANDLEBAR SWITCH (RIGHT), METER LEAD, HEADLIGHT HARNESS IGNITION COIL CONNECTOR ECU EXUP LEAD THROTTLE BODY LEAD MAIN SWITCH, SELECTOR SWITCH LEAD HEADLIGHT HARNESS POSITIVE BATTERY LEAD PASS ON INSIDE OF BATTERY BAND FUSE BOX (REMOVE FLASHER RELAY) STARTE
2-3 Chassis Parts 15. Oil Catcher Tank Set (5VY-C1707-70) Parts List Q’TY REMARKS CATCH TANK COMP. 1 Capacity: 630 cc 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 * No. PART No.
16. Chasis Protector Set (5VY-C117G-70) Parts List No. PART No. PART NAME Q’TY 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 REMARKS FWD FRAME FRAME ENGINE RIGHT LEFT Remove the bolt holding the head and using the bolt supplied, install the chassis protector and cut the cowling to fit the vehicle. 17. Rear Suspension Spring Parts List No. PART No.
18. Front Fork Spring Set 5VY-1244H-70 No. PART No. 1 5VY-23141-70 * 2 * 3 PART NAME Q’TY REMARKS FR. FORK SPRING 2 0,95 kgf/mm 5PW-23118-00 SPACER 2 4XV-23142-00 SEAT, SPRG UPPER 2 5VY-C3141-80 No. PART No. 1 5VY-23141-80 * 2 * 3 PART NAME Q’TY REMARKS FR. FORK SPRING 2 1,00 kgf/mm 5PW-23118-00 SPACER 2 4XV-23142-00 SEAT, SPRG UPPER 2 Specification –70 –80 STD Free length 255 mm 255 mm 236 mm Spring rate 0,95 kgf/mm 1,00 kgf/mm 0,90 kgf/mm No.
5VY-23111-00 3XJ-23147-L0 3XC-23357-00 2 3 1 19. Front Disk Assembly (5VY-2581T-70) Parts List No. PART No. PART NAME Q’TY 1 5VY-2582T-70 DISK, BRAKE Fr. 1 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 REMARKS t=5,0 1 3 5 4 2 This assembly is of the fully floating type, with the outer rotor 5 mm thick for improved durability when racing.
20. Front Wheel Attachment Set This fixing assembly is intended for the TZ250 Marchesini wheel.
21. Rear Arm Attachment Set, Rear Wheel Attachment Set Rear Arm Attachment Set (5VY-C2170-70) Parts List * * No. PART No. PART NAME Q’TY 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.
When using this set, it is necessary to reduce the length of the rear arm by 5 mm since contact is made between the rear arm and puller 2. SCRAPE AWAY 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.
Rear Wheel Attachment Set (4XV-C5310-80) Parts List No. PART No.
This fixing assembly is intended for Marchesini wheel 72186 (for Yamaha Super Bike). When using a different wheel, refer to the hub size below.
22. Sprocket, Sprocket Nut Parts List No. PART No. 1 4XV-17460-75 2 PART NAME Q’TY REMARKS SPROCKET, DRIVE 1 15T, 520SIZE 4XV-17460-76 SPROCKET, DRIVE 1 16T, 520SIZE 3 4XV-17460-77 SPROCKET, DRIVE 1 17T, 520SIZE 4 4XV-17463-70 NUT, SPROCKET 1 FOR KIT SPROCKETS 5 4XV-25441-70 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.
1 2 5 3 4 6 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°.
24. Footrest Set (5VY-C7400-70) Parts List No. PART No. 1 5SL-27412-70 BRKT., 1 1 2 5VY-27452-70 BRKT.
Install the rear brake return spring to 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.
25. Front Stay Set (5VY-C8350-70) Parts List No. PART No. PART NAME Q’TY 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 standard parts except for those supplied.
2-4 Other 26. Valve Seat Cutter Set Parts List 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.
3 Installation Precautions NOTE: Please check next point for setting up your motorcycle. 3-1 Checking the Valve Seats The following procedure applies to all valves and valve seats. 1. Eliminate : • lcarbon deposits (from the valve face and valve seat) 2. Check : • lvalve seat Pitting/wear ➔ replace cylinder head. 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) : 1.6 mm (0.06 in) a.
4. Lap : • lvalve face • lvalve seat NOTE: After replacing the cylinder head or the valve and the valve guide, the valve seat and valve face should be lapped. a. Apply a coarse lapping compound (a) to the valve face. CAUTION : Do not let the lapping compound enter the gap between the valve stem and the valve guide. b. Apply molybdenum disulfide oil on the valve stem. c. Install the valve in the cylinder head. d.
3-2 Selecting the crankshaft bearing 1. Read the crank journal size. 2. Read the crankcase journal size. (Read the size number 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.
3-3 Selecting the connecting rod bearing 1. Read the crank pin size. (Look at web 1 of the crankshaft.) 2. Read the big end size of the connecting rod (stamped on the connecting rod cap). 3. 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.
Connecting rod installation precautions 1. Install the connecting rod bearing onto the connecting rod with the projection in alignment. Apply oil generously to the bearing surface. 2. For installation, the word "YAMAHA" or the letter "Y" facing leftward. 3.
3-4 Installing the piston, piston ring, and connecting rod 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 Secure a clear a more ( in the c nce of 3 mm or lip mati ng pos ition) Mating position of the top ring and spacer CAUTION : Follow the procedure below to install the piston for the purpose of overhaul. 1.
When replacing a piston 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.
3-5 Crankcase installation Tightening the bolt a. 1. Follow the tightening sequence from 1 to 10 and tighten to a torque of 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.
3-6 Cylinder head tightening (calibrated wrench tightening method). 1. Temporarily tighten to 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.
3-7 Camshaft installation Timing matching Timing matching mark Timing matching mark - 49 -
3-8 Cam chain tension device installation To match the valve timing, use the oval holes in the standard sprocket. Install the tension device with its installation direction mark pointing upward. 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 will come off.
3-9 Engine mounting Temporarily fit g BOLT, ENG. ADJ. to the frame. Place the engine on the mounting location of the frame and temporarily fit e BOLT. Temporarily fit cd BOSS, ENG. MOUNT on the frame and temporarily fit ab BOLT. Tighten g BOLT, ENG. ADJ. to the specified torque. Check that the engine and the seating surface of g are in contact with one another. 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.
3-10 Front axle installation 1. Insert the front wheel axle on the right side and tighten b BOLT, FLG to 85 Nm on the left side. 2. Without preliminary tightening, fully tighten the bolts in the sequence pinch bolt 2, pinch bolt 1 and pinch bolt 2 to 10 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.
TIGHTENING TORQUE LIST Engine Tightening Point Part No. Part Name Thread dia. × pitch Tightening torque Nm (kgf•m) Q'ty Remarks Cylinder head tightening 90176-10075 Nut M10 × 1,25 Turn-of-nut method: Retighten to 135±5 degrees after tightening to 42 (4.2). 2 Apply oil to thread and seating surface. Cylinder head tightening 90179-10006 Nut M10 × 1,25 Turn-of-nut method: Retighten to 135±5 degrees after tightening to 33 (3.3). 8 Apply oil to thread and seating surface.
Engine Tightening Point Part No. Part Name Thread dia.
Chassis Tightening Point Part No. Part Name Thread dia.
- 56 - Headlight cord wiring diagram
2004 YZF-R1 Wiring Diagram - 57 -
YEC CO.,LTD. 3622-8 Nishikaizuka. Iwata. Shizuoka. 438-0026 Japan Tel.
