drain bolt YAMAHA YZF-R1SC 2004 User Guide

4-37
FRONT AND REAR BRAKESCHAS
NOTE:
NOTE:
WARNING
EAS00625
DISASSEMBLING THE FRONT BRAKE
CALIPERS
The following procedure applies to both of the
brake calipers.
Before disassembling the brake caliper, drain
the brake fluid from the entire brake system.
1. Remove:

union bolt
1

copper washers 2

brake hose 3
Put the end of the brake hose into a container
and pump out the brake fluid carefully.
2. Remove:

brake caliper pistons
1

brake caliper piston seals 2
a. Secure the brake caliper pistons with a piece
of wood
a.
b. Blow compressed air into the brake hose
joint opening
b to force out the left side pis-
tons from the brake caliper.

Never try to pry out the brake caliper pis-
tons.

Do not loosen the bolts
3.
c. Remove the brake caliper piston seals.
d. Repeat the previous steps to force out the
right side pistons from the brake caliper.
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4-38
FRONT AND REAR BRAKESCHAS
NOTE:
NOTE:
WARNING
EAS00626
DISASSEMBLING THE REAR BRAKE
CALIPER
Before disassembling the brake caliper, drain
the brake fluid from the entire brake system.
1. Remove:

union bolt
1

copper washers 2

brake hose 3

brake caliper 4
Put the end of the brake hose into a container
and pump out the brake fluid carefully.
2. Remove:

brake caliper piston
1

brake caliper piston seals 2
a. Secure the brake caliper piston with a piece
of wood
a.
b. Blow compressed air into the brake hose
joint opening
b to force out the piston from
the brake caliper.

Cover the brake caliper piston with a rag.
Be careful not to get injured when the pis-
ton is expelled from the brake caliper.

Never try to pry out the brake caliper pis-
ton.
c. Remove the brake caliper piston seals.
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4-48
FRONT FORKCHAS
NOTE:
WARNING
NOTE:
CAUTION:
EAS00652
DISASSEMBLING THE FRONT FORK LEGS
The following procedure applies to both of the
front fork legs.
1. Remove:

cap bolt
1
(from the damper adjusting rod)

spacer
2

nut 3
a. Press down on the spacer with the fork
spring compressor
4.
b. Install the rod holder
5 between the nut 3
and the spacer 2.
Fork spring compressor
90890-01441, YM-01441
Rod holder
90890-01434, YM-01434
Use the side of the rod holder that is marked “B”.
c. Loosen the nut.
d. Remove the cap bolt.
e. Remove the rod holder and fork spring com-
pressor.
The fork spring is compressed.
f. Remove the spacer and nut.
2. Drain:

fork oil
Stroke the damper rod
1 several times while
draining the fork oil.
3. Remove:

dust seal

oil seal clip
1

oil seal

washer
(with a flat-head screwdriver)
Do not scratch the inner tube.
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5-38
STARTER CLUTCH AND GENERATORENG
NOTE: REMOVING THE GENERATOR
1. Remove:

rider seat

fuel tank
Refer to “SEATS” and “FUEL TANK” in chapter
3.
2. Remove:

left side cowling

bottom cowlings
Refer to “COWLINGS” in chapter 3.
3. Drain:

engine oil
Refer to “CHANGING THE ENGINE OIL” in
chapter 3.
4. Remove:

plug

generator rotor cover
1

While pushing generator rotor, remove the
generator rotor cover.

Loosen each bolt 1 / 4 of a turn a time, in stages
and in a crisscross pattern.

After all of the bolts are fully loosened, remove
them.
5. Remove:

generator rotor and starter clutch assembly
1.
6. Remove:

idler gear shaft bolt
1

idler shaft

idler gear
2
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5-44
CRANKSHAFT POSITION SENSORENG
NOTE:
12 Nm (1.2 m
kg, 8.7 ft
lb)
10 Nm (1.0 m
kg, 7.2 ft
lb)
REMOVING THE CRANKSHAFT POSITION
SENSOR
1. Remove:

rider seat

fuel tank
Refer to “SEATS” and “FUEL TANK” in chap-
ter 3.
2. Remove:

right side cowling

bottom cowlings
Refer to “COWLINGS” in chapter 3.
3. Drain:

engine oil
Refer to “CHANGING THE ENGINE OIL” in
chapter 3.
4. Disconnect:

crankshaft position sensor lead coupler
5. Remove:

crankshaft position sensor

O-ring

pickup rotor cover
1
Loosen each bolt 1 / 4 of a turn a time, in stages
and in a crisscross pattern.
After all of the bolts are fully loosened, remove
them.
INSTALLING THE CRANKSHAFT POSITION
SENSOR
1. Install:

gasket
New

pickup rotor cover
1

O-ring New

crankshaft position sensor
LOCTITE
2. Connect:

crankshaft position sensor lead coupler
3. Fill:

engine oil
Refer to “CHANGING THE ENGINE OIL” in
chapter 3.
4. Install:

right side cowling

bottom cowlings
Refer to “COWLINGS” in chapter 3.
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5-71
OIL PAN AND OIL PUMPENG
12 Nm (1.2 m
kg, 8.7 ft
lb)
10 Nm (1.0 m
kg, 7.2 ft
lb)
43Nm (4.3 m
kg, 31 ft
lb)
WARNING
NOTE:
EAS00380
INSTALLING THE OIL PAN
1. Install:

dowel pins

gasket
New

oil pan
1

oil level switch 2

engine oil drain bolt 3
Always use new copper washers.

Tighten the oil pan bolts in stages and in a
crisscross pattern.

Lubricate the oil level switch O-ring with en-
gine oil.
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6-5
Order Job / Part Q’ty Remarks
1
2
3
4
5
6
7
8
9Removing the oil cooler
Engine oil
Oil cooler inlet hose
Bolt
Washer
Oil cooler
O-ring
Water pump outlet pipe
O-ring
Water jacket joint inlet hose
O-ring1
1
1
1
1
1
1
1
1Remove the parts in the order listed.
Drain.
Refer to “CHANGING THE ENGINE OIL”
in chapter 3.
10 Nm (1.0 m
kg, 7.2 ft
lb)
10 Nm (1.0 m
kg, 7.2 ft
lb)
63 Nm (6.3 m
kg, 46 ft
lb)
OIL COOLERCOOL
EAS00457
OIL COOLER
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