wheel YAMAHA YZF-R1SC 2004 User Guide

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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3-59
AB
CHECKING THE TIRES
CHK
ADJ
WARNING
WARNING
2. Check:

tire surfaces
Damage / wear
Replace the tire.
Minimum tire tread depth
1.6 mm (0.06 in)
1Tire tread depth
2Sidewall
3Wear indicator

Do not use a tubeless tire on a wheel de-
signed only for tube tires to avoid tire fail-
ure and personal injury from sudden defla-
tion.

When using a tube tire, be sure to install the
correct tube.

Always replace a new tube tire and a new
tube as a set.

To avoid pinching the tube, make sure the
wheel rim band and tube are centered in the
wheel groove.

Patching a punctured tube is not recom-
mended. If it is absolutely necessary to do
so, use great care and replace the tube as
soon as possible with a good quality re-
placement.
ATire
BWheel
Tube wheelTube tire only
T beless wheelTube or tubelessTubeless wheeltire
After extensive tests, the tires listed below
have been approved by Yamaha Motor Co.,
Ltd. for this model. The front and rear tires
should always be by the same manufacturer
and of the same design. No guarantee con-
cerning handling characteristics can be giv-
en if a tire combination other than one ap-
proved by Yamaha is used on this
motorcycle.
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3-60
CHECKING THE TIRES / CHECKING THE WHEELS
CHK
ADJ
WARNING
NOTE:
WARNING
NOTE: Front tire
Manufacturer
SizeModel
DUNLOP120 / 70ZR 17
M / C (58W)D218FL
MICHELIN120 / 70ZR 17
M / C (58W)Pilot
POWER C
Rear tire
Manufacturer
SizeModel
DUNLOP190 / 50ZR 17
M / C (73W)D218L
MICHELIN190 / 50ZR 17
M / C (73W)Pilot
POWER G
New tires have a relatively low grip on the
road surface until they have been slightly
worn. Therefore, approximately 100 km
should be traveled at normal speed before
any high-speed riding is done.
For tires with a direction of rotation mark
1:

Install the tire with the mark pointing in the
direction of wheel rotation.

Align the mark
2 with the valve installation
point.
EAS00168
CHECKING THE WHEELS
The following procedure applies to both of the
wheels.
1. Check:

wheel
Damage / out-of-round
Replace.
Never attempt to make any repairs to the
wheel.
After a tire or wheel has been changed or re-
placed, always balance the wheel.
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4-1
4
FRONT WHEEL AND BRAKE DISCSCHAS
Order Job / Part Q’ty Remarks
1
2
3
4
5
6
7
8
9
10Removing the front wheel and brake
discs
Side reflector (left and right)
Brake hose holder (left and right)
Side reflector bracket
Front brake caliper (left and right)
Front wheel axle pinch bolt
Front wheel axle bolt
Front wheel axle
Collar (left and right)
Front wheel
Front brake disc (left and right)2
2
2
2
4
1
1
2
1
2Remove the parts in the order listed.
Place the motorcycle on a suitable stand
so that the front wheel is elevated.
For installation, reverse the removal
procedure.
NOTE:
35 Nm (3.5 m
kg, 25 ft
lb)
6 Nm (0.6 m
kg, 4.3 ft
lb)
91 Nm (9.1 m
kg, 66 ft
lb)
20 Nm (2.0 m
kg, 13 ft
lb)
6 Nm (0.6 m
kg, 4.3 ft
lb)
18 Nm (1.8 m
kg, 13 ft
lb)
2 Nm (0.2 m
kg, 1.4 ft
lb)
2 Nm (0.2 m
kg, 1.4 ft
lb)
EAS00514
CHASSIS
FRONT WHEEL AND BRAKE DISCS
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4-2
FRONT WHEEL AND BRAKE DISCSCHAS
Order Job / Part Q’ty Remarks
Disassembling the front wheel
Oil seal (left and right)
Wheel bearing (left and right)
Spacer2
2
1Disassemble the parts in the order listed.
For assembly, reverse the disassembly
procedure.
1
2
3
EAS00518
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4-3
FRONT WHEEL AND BRAKE DISCSCHAS
WARNING
NOTE:
NOTE:
NOTE:
WARNING
EAS00521
REMOVING THE FRONT WHEEL
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. Remove:

left brake caliper

right brake caliper
Refer to “FRONT BRAKE CALIPERS”.
Do not apply the brake lever when removing the
brake calipers.
3. Elevate:

front wheel
Place the motorcycle on a suitable stand so that
the front wheel is elevated.
4. Loosen :

front wheel axle pinch bolt
5. Remove :

front wheel axle bolt

front wheel axle

front wheel
EAS00525
CHECKING THE FRONT WHEEL
1. Check:

wheel axle
Roll the wheel axle on a flat surface.
Bends
Replace.
Do not attempt to straighten a bent wheel
axle.
2. Check:

tire

front wheel
Damage / wear
Replace.
Refer to “CHECKING THE TIRES” and
“CHECKING THE WHEELS” in chapter 3.
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4-4
FRONT WHEEL AND BRAKE DISCSCHAS
NOTE:
CAUTION:
NOTE:
3. Measure:

radial wheel runout
1

lateral wheel runout 2
Over the specified limits
Replace.
Radial wheel runout limit
1.0 mm (0.04 in)
Lateral wheel runout limit
0.5 mm (0.02 in)
4. Check:

wheel bearings
Front wheel turns roughly or is loose
Re-
place the wheel bearings.

oil seals
Damage / wear
Replace.
5. Replace:

wheel bearings
New

oil seals
New
a. Clean the outside of the front wheel hub.
b. Remove the oil seals
1 with a flat-head
screwdriver.
To prevent damaging the wheel, place a rag
2
between the screwdriver and the wheel surface.
c. Remove the wheel bearings
3 with a gener-
al bearing puller.
d. Install the new wheel bearings and oil seals
in the reverse order of disassembly.
Do not contact the wheel bearing inner race
1 or balls 2. Contact should be made only
with the outer race
3.
Use a socket
4 that matches the diameter of
the wheel bearing outer race and oil seal.
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4-5
FRONT WHEEL AND BRAKE DISCSCHAS
NOTE:
EAS00533
CHECKING THE BRAKE DISCS
The following procedure applies to all of the
brake discs.
1. Check:

brake disc
Damage / galling
Replace.
2. Measure:

brake disc deflection
Out of specification
Correct the brake disc
deflection or replace the brake disc.
Brake disc deflection limit
(maximum)
Front : 0.1 mm (0.004 in)
Rear : 0.15 mm (0.006 in)
a. Place the motorcycle on a suitable stand so
that the wheel is elevated.
b. Before measuring the front brake disc deflec-
tion, turn the handlebars to the left or right to
ensure that the front wheel is stationary.
c. Remove the brake caliper.
d. Hold the dial gauge at a right angle against
the brake disc surface.
e. Measure the deflection 1.5 mm (0.06 in) be-
low the edge of the brake disc.
3. Measure:

brake disc thickness
Measure the brake disc thickness at a few
different locations.
Out of specification
Replace.
Brake disc thickness limit
(minimum)
Front : 4.0 mm (0.16 in)
Rear : 4.5 mm (0.18 in)
4. Adjust:

brake disc deflection
a. Remove the brake disc.
b. Rotate the brake disc by one bolt hole.
c. Install the brake disc.
Tighten the brake disc bolts in stages and in a
crisscross pattern.
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4-6
FRONT WHEEL AND BRAKE DISCSCHAS
NOTE:
91 Nm (9.1 m
kg, 66 ft
lb)
20 Nm (2.0 m
kg, 14 ft
lb)
CAUTION:
Brake disc bolt
Front : 18 Nm (1.8 m
kg, 13 ft
lb)
Rear : 30 Nm (3.0 m
kg, 22 ft
lb)
LOCTITE

d. Measure the brake disc deflection.
e. If out of specification, repeat the adjustment
steps until the brake disc deflection is within
specification.
f. If the brake disc deflection cannot be brought
within specification, replace the brake disc.
EAS00545
INSTALLING THE FRONT WHEEL
The following procedure applies to both brake
discs.
1. Lubricate:

wheel axle

oil seal lips
Recommended lubricant
Lithium-soap-based grease
2. Lift the wheel up between the fork legs.
3. Insert the wheel axle.
Install the tire and wheel with the mark
1 point-
ing in the direction of wheel rotation.
4. Lower the front wheel so that it is on the
ground.
5. Tighten:

wheel axle

wheel axle pinch bolt
Before tightening the wheel axle nut, push
down hard on the handlebars several times
and check if the front fork rebounds smooth-
ly.
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