🏷️ Basic Information

Make:

Yamaha

Model:

YZF-R1

Model Year:

2004

Product Name:

Yamaha YZFR1 Service parts owners & racing kit Manual 2004 PDF Download

Internal Code:

YZFR1_2004_SM_RPK

👋 Introduction

Segment:

Supersport Motorcycle

Target Audience:

Enthusiasts, mechanics, track day riders, racers, and owners seeking in-depth maintenance and repair knowledge.

Key Competitors 2004:

Honda CBR1000RR, Suzuki GSX-R1000, Kawasaki ZX-10R, Ducati 999

Engine Layout:

Inline-four cylinder, DOHC, 5-valve per cylinder

Chassis Design:

Deltabox frame, optimized weight distribution for agility and stability.

Aerodynamics:

Aggressive fairing design for reduced drag and improved rider protection at high speeds.

Manual Value Proposition:

Provides comprehensive technical data, repair procedures, and diagnostic information essential for maintaining peak performance and longevity of the YZF-R1.

📋 Manual Details

Manual Types Included:

Service Manual, Owner's Manual, Racing Kit Manual

Total Pages:

457

Primary Manual Type:

Service Manual

Language:

English

Format:

PDF Download

📖 Manual Coverage

Engine Management:

Fuel injection, ignition timing, sensor diagnostics, ECU troubleshooting

Powertrain:

Engine assembly, transmission, clutch operation, final drive

Chassis And Suspension:

Front forks, rear shock absorber, swingarm, steering system, frame inspection

Braking System:

Front and rear brake caliper service, master cylinder, fluid lines, bleeding procedures

Electrical System:

Wiring diagrams, lighting, charging system, starter, ignition coils, sensor testing

Fuel System:

Fuel tank, fuel pump, injectors, pressure regulator, evaporative emission control (EVAP)

Cooling System:

Radiator, fan, coolant flow, thermostat, water pump

Exhaust System:

Exhaust manifold, catalytic converter, mufflers, lambda sensors

Bodywork And Trim:

Fairing removal and installation, seat, fuel tank cover, body panel alignment

Routine Maintenance:

Oil changes, filter replacements, chain adjustment, spark plug service, brake pad inspection

Troubleshooting Diagnostics:

Fault code interpretation, systematic problem diagnosis for all major systems

Engine Rebuilding:

Top-end overhaul, piston and cylinder inspection, crankshaft and bearing service, valve clearance adjustment

Transmission Overhaul:

Gearbox disassembly, clutch component replacement, shift drum and fork inspection

Suspension Setup And Rebuild:

Fork seal replacement, damper rod service, shock absorber re-valving basics

Electrical Component Testing:

Testing of starter motor, alternator, stator, regulator/rectifier, sensors, and ECU

Brake System Overhaul:

Caliper piston replacement, seal kits, bleeding procedures, master cylinder rebuild

Depth Of Coverage:

Comprehensive: from basic owner maintenance to complete engine and transmission rebuilds, including detailed electrical diagnostics and racing modifications.

Diagnostic Focus:

Includes diagnostic codes (DTCs), specific testing procedures for sensors and actuators, and troubleshooting flowcharts.

Racing Kit Coverage:

Likely includes information on performance enhancements, ECU remapping considerations, suspension tuning for track use, and component compatibility for racing applications.

📊 Manual Specifications

File Type:

PDF (Portable Document Format)

Searchability:

Likely text-searchable, enabling quick keyword-based information retrieval.

Diagram Quality:

High quality, allowing for clear identification of components and assembly sequences.

Binding:

N/A (Digital PDF Download)

Paper Type:

N/A (Digital PDF Download)

⚙️ Engine Specifications

Engine Type:

998cc, Liquid-cooled, 4-stroke, DOHC, 5-valve per cylinder

Bore X Stroke:

74.0 mm x 58.0 mm

Compression Ratio:

12.1:1

Horsepower:

Approximately 152 hp @ 10,000 rpm (claimed)

Torque:

Approximately 10.6 kg-m (77.4 lb-ft) @ 8,500 rpm (claimed)

Fuel Delivery:

Fuel Injection with dual injectors per cylinder

Ignition System:

TCI (Transistor Controlled Ignition)

Oil Type Recommendation:

Yamalube 4 (or equivalent) SAE 10W-40 or 20W-50

Oil Capacity With Filter Change:

3.60 L (3.80 US qt)

Coolant Type:

Permanent type antifreeze coolant (50% solution)

🔧 Transmission

Transmission Type:

6-speed, constant mesh

Clutch Type:

Wet, multiple-disc

Gear Ratios:

Primary drive: 1.621 (47/29); Gear ratios: 1st: 2.545 (30/11), 2nd: 1.944 (35/18), 3rd: 1.555 (28/18), 4th: 1.333 (32/24), 5th: 1.159 (27/23), 6th: 1.036 (29/28)

Final Drive:

O-ring sealed chain

Transmission Oil Capacity:

0.90 L (0.95 US qt)

Transmission Oil Type:

Yamalube 4 (or equivalent) SAE 10W-30 or 20W-40

📐 Dimensions

Length:

2,060 mm (81.1 in)

Width:

720 mm (28.3 in)

Height:

1,125 mm (44.3 in)

Wheelbase:

1,405 mm (55.3 in)

Ground Clearance:

130 mm (5.1 in)

Dry Weight:

176 kg (388 lbs)

Wet Weight:

202 kg (445 lbs) (approximate, with all fluids)

Fuel Tank Capacity:

18.0 L (4.8 US gal)

🛡️ Safety Features

Safety Standards:

Designed to meet global motorcycle safety standards.

Braking System:

Dual 320mm hydraulic disc front brakes, Single 220mm hydraulic disc rear brake.

Suspension Design:

Advanced suspension geometry for stability and control under braking and acceleration.

Frame Construction:

Rigid Deltabox frame for chassis integrity.

💡 Technology Features

Instrument Cluster:

Multi-function digital LCD display with analog tachometer. Includes speed, RPM, odometer, trip meters, fuel gauge, clock, coolant temperature, and diagnostic indicators.

Electronic Aids:

No advanced electronic rider aids such as traction control or ABS were standard on the 2004 R1 model. Focus is on raw performance and rider input.

Diagnostics Port:

Diagnostic connector for connecting diagnostic tools for fault code retrieval and parameter monitoring.

🔧 Maintenance

Oil And Filter Change:

Every 6,000 km (3,700 miles) or 6 months, whichever comes first.

Air Filter Inspection:

Every 6,000 km (3,700 miles).

Spark Plug Replacement:

Every 12,000 km (7,500 miles).

Valve Clearance Check:

First check at 18,000 km (11,200 miles), then every 12,000 km (7,500 miles).

Brake Fluid Flush:

Every 2 years or as needed.

Engine Oil Specification:

API SG, SF or SFC motorcycle oil, JASO MA approved, SAE 10W-40 or 20W-50.

Coolant Specification:

Ethylene glycol-based permanent type antifreeze coolant (50% mixture with distilled water).

Brake Fluid Specification:

DOT 4 approved.

Common Wear Items:

Clutch plates, brake pads, chain and sprockets, fork seals, wheel bearings.

Potential Electrical:

While generally reliable, stator output and regulator/rectifier function should be periodically checked, especially under heavy electrical load or high mileage.

Fuel System Maintenance:

Regular cleaning of fuel injectors and checking fuel filter for debris is recommended for optimal performance.

📚 Vehicle History

Yamaha Legacy:

Yamaha Motor Company has a long-standing history of producing high-performance motorcycles, known for innovation in engine technology and chassis dynamics.

R1 Lineage:

The YZF-R1 was introduced in 1998, revolutionizing the supersport category. The 2004 model represents the fourth generation, featuring significant updates including fuel injection and chassis refinements.

Manufacturing Origin:

Japan

🏆 Awards & Recognition

Motorcycle Of The Year Nominations:

The YZF-R1 consistently received high praise and accolades from motorcycle publications upon its release and throughout its model run for its performance and handling.

Performance Reviews:

Highly rated by motorcycle journalists for its powerful engine, sharp handling, and track-day capability.