YAMAHA YZF-R1SC 2004 Service Manual

3-44
A
B
CHECKING THE BRAKE FLUID LEVEL
CHK
ADJ
NOTE:
WARNING
CAUTION:
NOTE:
EAS00115
CHECKING THE BRAKE FLUID LEVEL
1. Stand the motorcycle on a level surface.

Place the motorcycle on a suitable stand.

Make sure the motorcycle is upright.
2. Check:

brake fluid level
Below the minimum level mark
a
Add the
recommended brake fluid to the proper level.
Recommended brake fluid
DOT 4
AFront brake
BRear brake

Use only the designated brake fluid. Other
brake fluids may cause the rubber seals to
deteriorate, causing leakage and poor
brake performance.

Refill with the same type of brake fluid that
is already in the system. Mixing brake
fluids may result in a harmful chemical
reaction, leading to poor brake perfor-
mance.

When refilling, be careful that water does
not enter the brake fluid reservoir. Water
will significantly lower the boiling point of
the brake fluid and could cause vapor lock.
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean
up any spilt brake fluid immediately.
In order to ensure a correct reading of the brake
fluid level, make sure the top of the brake fluid
reservoir is horizontal.
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3-45
ADJUSTING THE REAR BRAKE LIGHT SWITCH /
CHECKING THE FRONT AND REAR BRAKE PADSCHK
ADJ
NOTE:
a
b
EAS00128
ADJUSTING THE REAR BRAKE LIGHT
SWITCH
The rear brake light switch is operated by move-
ment of the brake pedal.
The rear brake light switch is properly adjusted
when the brake light comes on just before the
braking effect starts.
1. Check:

rear brake light operation timing
Incorrect
Adjust.
2. Adjust:

rear brake light operation timing
a. Hold the main body
1 of the rear brake light
switch so that it does not rotate and turn the
adjusting nut
2 in direction a or b until the
rear brake light comes on at the proper time.
Direction
Brake light comes on
sooner.
DirectionBrake light comes on
later.
EAS00122
CHECKING THE FRONT AND REAR BRAKE
PADS
The following procedure applies to all of the
brake pads.
1. Operate the brake.
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3-46
B
A
B
A
CHECKING THE FRONT AND REAR BRAKE PADS
/
CHECKING THE FRONT AND REAR BRAKE HOSESCHK
ADJ
2. Check:

front brake pad

rear brake pad
Brake pad wear limit
a, b
Wear limit reached
Replace the brake
pads as a set.
Refer to “FRONT AND REAR BRAKES” in
chapter 7.
Brake pad wear limit
a 0.5 mm (0.02 in)
b 1.0 mm (0.04 in)
AFront brake
BRear brake
EAS00131
CHECKING THE FRONT AND REAR BRAKE
HOSES
The following procedure applies to all of the
brake hoses and brake hose clamps.
1. Check:

brake hose
1
Cracks / damage / wear
Replace.
AFront
BRear
2. Check:

brake hose clamp
2
Loose
Tighten the clamp bolt.
3. Hold the motorcycle upright and apply the
brake several times.
4. Check:

brake hose
Brake fluid leakage
Replace the damaged
hose.
Refer to “FRONT AND REAR BRAKES” in
chapter 4.
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3-47
B
C
A
BLEEDING THE HYDRAULIC BRAKE SYSTEM
CHK
ADJ
WARNING
NOTE:
NOTE:
EAS00135
BLEEDING THE HYDRAULIC BRAKE
SYSTEM
Bleed the hydraulic brake system whenev-
er:

the system is disassembled.

a brake hose is loosened, disconnected or
replaced.

the brake fluid level is very low.

brake operation is faulty.

Be careful not to spill any brake fluid or allow
the brake fluid reservoir to overflow.

When bleeding the hydraulic brake system,
make sure there is always enough brake fluid
before applying the brake. Ignoring this pre-
caution could allow air to enter the hydraulic
brake system, considerably lengthening the
bleeding procedure.

If bleeding is difficult, it may be necessary to let
the brake fluid settle for a few hours. Repeat
the bleeding procedure when the tiny bubbles
in the hose have disappeared.
1. Bleed:

hydraulic brake system
a. Fill the brake fluid reservoir to the proper lev-
el with the recommended brake fluid.
b. Install the brake fluid reservoir diaphragm.
c. Connect a clear plastic hose
1 tightly to the
bleed screw
2.
AFront brake master cylinder
BFront brake caliper
CRear brake caliper
Bleeding order of the front hydraulic brake sys-
tem is the following order:
1. front brake master cylinder.
2. front brake calipers.
3. front brake master cylinder.
d. Place the other end of the hose into a con-
tainer.
e. Slowly apply the brake several times.
f. Fully pull the brake lever or fully press down
the brake pedal and hold it in position.
g. Loosen the bleed screw.
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3-48
BLEEDING THE HYDRAULIC BRAKE SYSTEM /
ADJUSTING THE SHIFT PEDALCHK
ADJ
NOTE:
WARNING
NOTE:
a
b
Loosening the bleed screw will release the pres-
sure and cause the brake lever to contact the
throttle grip or the brake pedal to fully extend.
h. Tighten the bleed screw and then release the
brake lever or brake pedal.
i. Repeat steps (e) to (h) until all of the air
bubbles have disappeared from the brake
fluid in the plastic hose.
j. Tighten the bleed screw to specification.
Bleed screw
6 Nm (0.6 m
kg, 4.3 ft
lb)
k. Fill the brake fluid reservoir to the proper lev-
el with the recommended brake fluid.
Refer to “CHECKING THE BRAKE FLUID
LEVEL”.
After bleeding the hydraulic brake system,
check the brake operation.
After bleeding air, the brake fluid may ooze
around the thread section of each bleed screw.
This phenomenon does not show the leakage
but the brake fluid that has been accumulated in
the thread of screw while bleeding air. Please
wipe off to make the parts clean.
EAS00136
ADJUSTING THE SHIFT PEDAL
1. Adjust:

shift pedal position
a. Loosen both locknuts
1.
b. Turn the shift rod
2 in direction a or b to
obtain the correct shift pedal position.
Direction
Shift pedal is raised.
DirectionShift pedal is lowered.
c. Tighten both locknuts.
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3-49
ADJUSTING THE DRIVE CHAIN SLACK
CHK
ADJ
NOTE:
CAUTION:
WARNING
NOTE:
EAS00140
ADJUSTING THE DRIVE CHAIN SLACK
The drive chain slack must be checked at the
tightest point on the chain.
A drive chain that is too tight will overload
the engine and other vital parts, and one that
is too loose can skip and damage the swin-
garm or cause an accident. Therefore, keep
the drive chain slack within the specified
limits.
1. Stand the motorcycle on a level surface.
Securely support the motorcycle so that
there is no danger of it falling over.
Place the motorcycle on a suitable stand so that
the rear wheel is elevated.
2. Spin the rear wheel several times and find
the tightest position of drive chain.
3. Check:

drive chain slack
a
Out of specification
Adjust.
Drive chain slack
25
35 mm (0.98
1.38 in)
4. Adjust:

drive chain slack
a. Loosen the wheel axle nut
1.
b. Loosen both locknuts
2.
c. Turn both adjusting bolts
3 in direction a or
b until the specified drive chain slack is ob-
tained.
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3-50
a
b
ADJUSTING THE DRIVE CHAIN SLACK /
LUBRICATING THE DRIVE CHAINCHK
ADJ
NOTE:
DirectionDrive chain is tightened.
DirectionDrive chain is loosened.
To maintain the proper wheel alignment, adjust
both sides evenly.
d. Tighten both locknuts to specification.
Locknut
16 Nm (1.6 m
kg, 12 ft
lb)
e. Tighten the wheel axle nut to specification.
Wheel axle nut
150 Nm (15 m
kg, 108 ft
lb)
EAS00142
LUBRICATING THE DRIVE CHAIN
The drive chain consists of many interacting
parts. If the drive chain is not maintained proper-
ly, it will wear out quickly. Therefore, the drive
chain should be serviced, especially when the
motorcycle is used in dusty areas.
This motorcycle has a drive chain with small
rubber O-rings between each side plate. Steam
cleaning, high-pressure washing, certain sol-
vents, and the use of a coarse brush can dam-
age these O-rings. Therefore, use only kero-
sene to clean the drive chain. Wipe the drive
chain dry and thoroughly lubricate it with engine
oil or chain lubricant that is suitable for O-ring
chains. Do not use any other lubricants on the
drive chain since they may contain solvents that
could damage the O-rings.
Recommended lubricant
Engine oil or chain lubricant
suitable for O-ring chains
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3-51
CHECKING AND ADJUSTING THE STEERING HEAD
CHK
ADJ
WARNING
NOTE:
NOTE:
EAS00146
CHECKING AND ADJUSTING THE
STEERING HEAD
1. Stand the motorcycle on a level surface.
Securely support the motorcycle so that
there is no danger of it falling over.
Place the motorcycle on a suitable stand so that
the front wheel is elevated.
2. Check:

steering head
Grasp the bottom of the front fork legs and
gently rock the front fork.
Binding / looseness
Adjust the steering
head.
3. Remove:

upper bracket
Refer to “HANDLEBAR” and “STEERING
HEAD” in chapter 4.
4. Adjust:

steering head
a. Remove the lock washer
1, the upper ring
nut
2, and the rubber washer 3.
b. Loosen the lower ring nut
4 and then tighten
it to specification with a steering nut wrench
5.
Set the torque wrench at a right angle to the
steering nut wrench.
Steering nut wrench
90890-01403, YU-33975
Lower ring nut (initial tightening
torque)
52 Nm (5.2 m
kg, 38 ft
lb)
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3-52
CHECKING AND ADJUSTING THE STEERING HEAD
CHK
ADJ
WARNING
NOTE:
NOTE: c. Loosen the lower ring nut
4 completely, then
tighten it to specification.
Do not overtighten the lower ring nut.
Lower ring nut
(final tightening torque)
18 Nm (1.8 m
kg, 13 ft
lb)
d. Check the steering head for looseness or
binding by turning the front fork all the way in
both directions. If any binding is felt, remove
the under bracket and check the upper and
lower bearings.
Refer to “STEERING HEAD” in chapter 4.
e. Install the rubber washer
3.
f. Install the upper ring nut
2.
g. Finger tighten the upper ring nut
2, then
align the slots of both ring nuts. If necessary,
hold the lower ring nut and tighten the upper
ring nut until their slots are aligned.
h. Install the lock washer
1.
Make sure the lock washer tabs
a sit correctly
in the ring nut slots
b.
5. Install:

upper bracket
Refer to “HANDLEBAR” and “STEERING
HEAD” in chapter 4.
6. Measure:

steering head tension
Make sure all of the cables and wires are prop-
erly routed.
a. Point the front wheel straight ahead.
b. Install a plastic locking tie
1 loosely around
the end of the handlebar as shown.
c. Hook a spring gauge
2 onto the plastic lock-
ing tie.
d. Hold the spring gauge at a 90 angle from the
handlebar, pull the spring gauge, and then
record the measurement when the handle-
bar starts to run.
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3-53
CHECKING AND ADJUSTING THE STEERING HEAD /
CHECKING THE FRONT FORKCHK
ADJ
WARNING
Steering head tension
200
500 g
e. Repeat the above procedure on the opposite
handlebar.
f. If the steering head tension is out of specifi-
cation (both handlebars should be within
specification), remove the upper bracket and
loosen or tighten the upper ring nut.
g. Reinstall the upper bracket and measure the
steering head tension again as described
above.
h. Repeat the above procedure until the steer-
ing head tension is within specification.
i. Grasp the bottom of the front fork legs and
gently rock the front fork.
Binding / looseness
Adjust the steering
head.
EAS00150
CHECKING THE FRONT FORK
1. Stand the motorcycle on a level surface.
Securely support the motorcycle so that
there is no danger of it falling over.
2. Check:

inner tube
1
Damage / scratches
Replace.

oil seal
2
Oil leakage
Replace.
3. Hold the motorcycle upright and apply the
front brake.
4. Check:

front fork operation
Push down hard on the handlebars several
times and check if the front fork rebounds
smoothly.
Rough movement
Repair.
Refer to “FRONT FORK” in chapter 4.
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