radiator YAMAHA YZF-R1SC 2004 User Guide

2-44
K Pass the water hose lower side
of the thermostat, and between
the ground lead and the neutral
switch.
L Install the leads so that the en-
gine ground lead is positioned
lower and the battery negative
lead to be upper. Install the pro-
trusion of each lead to be above
the vehicle.
M Route the crankshaft position
sensor lead under the wire har-
ness.
N To the fuel pump
O Clamp the wire harness winding
in and insert it to the frame hole.A Pass the wire harness through
the clamp inserted to the radiator
stay.
B To the headlight lead
C Clamp the lead between three
protrusions of the pipe (the first
and second parts from the ve-
hicle front). Point the tip of the
clamp (excessive part) to the in-
side of the vehicle.
D To the vehicle right side diagram
E To the engine
F Clamp the lead between three
protrusions of the pipe (the in-
side and outside of the vehicle).G Point the tip of the clamp (exces-
sive part) to the inside of the ve-
hicle.
H All hoses and leads should be
routed over the vehicle’s upper
side above the heat protector.
I To the starter motor
J Fasten the wire harness, clank
shaft position sensor lead, rear
brake light switch lead and
speed sensor lead with a clamp.
Then, point the tip of the clamp
(cut the tip of the clamp leaving 2
to 4 mm (0.08 to 0.16 in).) to the
inside of the vehicle.
CABLE ROUTINGSPEC
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3-11
ADJUSTING THE VALVE CLEARANCE
CHK
ADJ
NOTE:
EAS00045
ENGINE
ADJUSTING THE VALVE CLEARANCE
The following procedure applies to all of the
valves.

Valve clearance adjustment should be made
on a cold engine, at room temperature.

When the valve clearance is to be measured or
adjusted, the piston must be at top dead center
(TDC) on the compression stroke.
1. Remove

rider seat
Refer to “SEATS”.

fuel tank
Refer to “FUEL TANK”.

air filter case
Refer to “AIR FILTER CASE”.

bottom cowlings

side cowlings
Refer to “COWLINGS”.

throttle body assembly
Refer to “THROTTLE BODIES” in chapter 7.

air cut-off valve
Refer to “AIR INDUCTION SYSTEM” in
chapter 7.

radiator

radiator fan motor
Refer to “RADIATOR” in chapter 6.
2. Remove

ignition coils

spark plugs

cylinder head cover

cylinder head cover gasket
Refer to “CAMSHAFT” in chapter 5.
3. Remove

pickup rotor cover
1
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3-23
CHECKING THE SPARK PLUGS
CHK
ADJ
CAUTION:
EAS00059
CHECKING THE SPARK PLUGS
The following procedure applies to all of the
spark plugs.
1. Remove:

side cowlings

bottom cowlings
Refer to “COWLINGS”.
2. Remove:

radiator upper bolts

radiator lower bolt
Refer to “RADIATOR” in chapter 6.
3. Remove:

ignition coils

spark plugs
Before removing the spark plugs, blow away
any dirt accumulated in the spark plug wells
with compressed air to prevent it from fal-
ling into the cylinders.
4. Check:

spark plug type
Incorrect
Change.
Spark plug type (manufacturer)
CR9EK (NGK)
5. Check:

electrode
1
Damage / wear
Replace the spark plug.

insulator
2
Abnormal color
Replace the spark plug.
Normal color is medium-to-light tan.
6. Clean:

spark plug
(with a spark plug cleaner or wire brush)
7. Measure:

spark plug gap
a
(with a wire Thickness gauge)
Out of specification
Regap.
Spark plug gap
0.6  0.7 mm
(0.0236  0.0276 in)
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3-24
CHECKING THE SPARK PLUGS /
MEASURING THE COMPRESSION PRESSURECHK
ADJ
13 Nm (1.3 m
kg, 9.4 ft
lb)
NOTE:
NOTE:
CAUTION:
8. Install:

spark plugs

ignition coils
Before installing the spark plug, clean the spark
plug and gasket surface.
9. Install:

radiator upper bolts

radiator lower bolt
Refer to “RADIATOR” in chapter 6.
10. Install:

side cowlings

bottom cowlings
Refer to “COWLINGS”.
EAS00065
MEASURING THE COMPRESSION
PRESSURE
The following procedure applies to all of the cyl-
inders.
Insufficient compression pressure will result in a
loss of performance.
1. Measure:

valve clearance
Out of specification
Adjust.
Refer to “ADJUSTING THE VALVE CLEAR-
ANCE”.
2. Start the engine, warm it up for several min-
utes, and then turn it off.
3. Remove:

ignition coils

spark plugs
Before removing the spark plugs, use com-
pressed air to blow away any dirt accumu-
lated in the spark plug wells to prevent it
from falling into the cylinders.
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3-38
CHECKING THE COOLING SYSTEM
CHK
ADJ
EAS00104
CHECKING THE COOLING SYSTEM
1. Remove:

bottom cowlings

side cowlings
Refer to “COWLINGS”.
2. Check:

radiator
1

radiator inlet hose 2

radiator outlet hose 3

oil cooler 4

oil cooler inlet hose 5

oil cooler outlet hose 6

water jacket joint 7

water jacket joint inlet hose 8

water pump inlet pipe 9

water pump outlet pipe 10
Cracks / damage
Replace.
Refer to “COOLING SYSTEM” in chapter 6.
3. Install:

side cowlings

bottom cowling
Refer to “COWLINGS”.
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3-39
CHANGING THE COOLANT
CHK
ADJ
CAUTION:
EAS00105
CHANGING THE COOLANT
1. Remove:

bottom cowlings

side cowlings
Refer to “COWLINGS”.

rider seat
Refer to “SEATS”.
2. Remove:

coolant reservoir tank

coolant reservoir hose
3. Disconnect:

coolant reservoir cap
1
4. Drain:

coolant
(from the coolant reservoir tank)
5. Remove:

radiator cap
1
A hot radiator is under pressure. Therefore,
do not remove the radiator cap when the en-
gine is hot. Scalding hot fluid and steam may
be blown out, which could cause serious in-
jury. When the engine has cooled, open the
radiator cap as follows:
Place a thick rag or a towel over the radiator
cap and slowly turn the radiator cap coun-
terclockwise toward the detent to allow any
residual pressure to escape. When the his-
sing sound has stopped, press down on the
radiator cap and turn it counterclockwise to
remove.
The following procedure applies to all of the
coolant drain bolts and copper washers.
6. Remove:

coolant drain bolts
1
(along with the copper washers)
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3-41
CHANGING THE COOLANT
CHK
ADJ
CAUTION:
NOTE:
Adding water instead of coolant lowers the
antifreeze content of the coolant. If water is
used instead of coolant check, and if nec-
essary, correct the antifreeze concentra-
tion of the coolant.

Use only distilled water. However, if dis-
tilled water is not available, soft water may
be used.

If coolant comes into contact with painted
surfaces, immediately wash them with wa-
ter.

Do not mix different types of antifreeze.
13. Install:

radiator cap
14. Fill:

coolant reservoir tank
(with the recommended coolant to the maxi-
mum level mark
a)
15. Install:

coolant reservoir cap
16. Start the engine, warm it up for several min-
utes, and then stop it.
17. Check:

coolant level
Refer to “CHECKING THE COOLANT LEV-
EL”.
Before checking the coolant level, wait a few
minutes until the coolant has settled.
18. Install:

rider seat
Refer to “SEATS”.

bottom cowlings

side cowlings
Refer to “COWLINGS”.
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3-68
CHECKING THE FUSES
CHK
ADJ
WARNING
Pocket tester
90890-03112, YU-3112
b. If the pocket tester indicates “∞”, replace the
fuse.
3. Replace:

blown fuse
a. Set the main switch to “OFF”.
b. Install a new fuse of the correct amperage
rating.
c. Set on the switches to verify if the electrical
circuit is operational.
d. If the fuse immediately blows again, check
the electrical circuit.
Fuses
Amperage
ratingQ’ty
Main50 A1
Fuel injection
system15 A1
Headlight25 A1
Signaling
system10 A1
Ignition15 A1
Backup fuse
(odometer
and clock)
10 A1
Radiator
fan motor15 A2
Reserve25 A, 15 A,
10 A1
Never use a fuse with an amperage rating
other than that specified. Improvising or us-
ing a fuse with the wrong amperage rating
may cause extensive damage to the electri-
cal system, cause the lighting and ignition
systems to malfunction and could possibly
cause a fire.
4. Install:

front cowling inner panel (left)
Refer to “COWLINGS”.

rider seat
Refer to “SEATS”.
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5-11
Order Job / Part Q’ty Remarks
1
2
3
4Removing the cylinder head cover
Fuel tank
Side and bottom cowlings
Throttle body assembly
Radiator assembly
Air cut-off valve
Ignition coil
Spark plug
Cylinder head cover
Cylinder head cover gasket4
4
1
1Remove the parts in the order listed.
Refer to “FUEL TANK” in chapter 3.
Refer to “COWLINGS” in chapter 3.
Refer to “THROTTLE BODIES” in
chapter 7.
Refer to “RADIATOR” in chapter 3.
Refer to “AIR INDUCTION SYSTEM” in
chapter 7.
13 Nm (1.3 m
kg, 9.4 ft
lb)
8 Nm (0.8 m
kg, 5.7 ft
lb)
12 Nm (1.2 m
kg, 8.7 ft
lb)
CAMSHAFTENG
EAS00194
CAMSHAFT
CYLINDER HEAD COVER
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6-1
Order Job / Part Q’ty Remarks
1
2
3
4
5Removing the radiator
Rider seat
Fuel tank
Air filter case
Side cowlings
Bottom cowling
Coolant
Fuse box stay
Coolant reservoir hose
Radiator
Radiator fan motor
Radiator inlet hose1
1
1
2
1Remove the parts in the order listed.
Refer to “AIR FILTER CASE” in chapter 3.
Drain.
Refer to “CHANGING THE COOLANT” in
chapter 3.
Disconnect.
Refer to “COWLINGS” in chapter 3.
Refer to “SEATS” in chapter 3.
10 Nm (1.0 m
kg, 7.2 ft
lb)
10 Nm (1.0 m
kg, 7.2 ft
lb)
5 Nm (0.5 m
kg, 3.6 ft
lb)
10 Nm (1.0 m
kg, 7.2 ft
lb)
RADIATORCOOL
EAS00454
COOLING SYSTEM
RADIATOR
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