battery YAMAHA YZF-R1SC 2004 Service Manual

CHASSIS3-42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ADJUSTING THE FRONT BRAKE 3-42. . . . . . . . . . . . . . . . . . . . . . . . . . .
ADJUSTING THE REAR BRAKE 3-43. . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE BRAKE FLUID LEVEL 3-44. . . . . . . . . . . . . . . . . . . . . .
ADJUSTING THE REAR BRAKE LIGHT SWITCH 3-45. . . . . . . . . . . . .
CHECKING THE FRONT AND REAR BRAKE PADS 3-45. . . . . . . . . . .
CHECKING THE FRONT AND REAR BRAKE HOSES 3-46. . . . . . . . .
BLEEDING THE HYDRAULIC BRAKE SYSTEM 3-47. . . . . . . . . . . . . . .
ADJUSTING THE SHIFT PEDAL 3-48. . . . . . . . . . . . . . . . . . . . . . . . . . . .
ADJUSTING THE DRIVE CHAIN SLACK 3-49. . . . . . . . . . . . . . . . . . . . .
LUBRICATING THE DRIVE CHAIN 3-50. . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING AND ADJUSTING THE STEERING HEAD 3-51. . . . . . . . .
CHECKING THE FRONT FORK 3-53. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ADJUSTING THE FRONT FORK LEGS 3-54. . . . . . . . . . . . . . . . . . . . . .
ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY 3-56. . . . .
CHECKING THE TIRES 3-58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE WHEELS 3-60. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING AND LUBRICATING THE CABLES 3-61. . . . . . . . . . . . . . .
LUBRICATING THE LEVERS AND PEDALS 3-61. . . . . . . . . . . . . . . . . .
LUBRICATING THE SIDESTAND 3-61. . . . . . . . . . . . . . . . . . . . . . . . . . . .
LUBRICATING THE REAR SUSPENSION 3-61. . . . . . . . . . . . . . . . . . . .
ELECTRICAL SYSTEM3-62 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING AND CHARGING THE BATTERY 3-62. . . . . . . . . . . . . . . . .
CHECKING THE FUSES 3-67. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REPLACING THE HEADLIGHT BULBS 3-69. . . . . . . . . . . . . . . . . . . . . .
ADJUSTING THE HEADLIGHT BEAMS 3-70. . . . . . . . . . . . . . . . . . . . . .
CHAPTER 4
CHASSIS
FRONT WHEEL AND BRAKE DISCS4-1 . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE FRONT WHEEL 4-3. . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE FRONT WHEEL 4-3. . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE BRAKE DISCS 4-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE FRONT WHEEL 4-6. . . . . . . . . . . . . . . . . . . . . . . . . . .
ADJUSTING THE FRONT WHEEL STATIC BALANCE 4-7. . . . . . . . .
REAR WHEEL AND BRAKE DISC4-9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REAR WHEEL 4-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REAR BRAKE DISC AND REAR WHEEL SPROCKET 4-10. . . . . . . . .
REMOVING THE REAR WHEEL 4-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE REAR WHEEL 4-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE REAR WHEEL DRIVE HUB 4-13. . . . . . . . . . . . . . . . .
CHECKING AND REPLACING THE REAR WHEEL
SPROCKET 4-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE REAR WHEEL 4-14. . . . . . . . . . . . . . . . . . . . . . . . . . . .
ADJUSTING THE REAR WHEEL STATIC BALANCE 4-14. . . . . . . . . . .
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2-15
ELECTRICAL SPECIFICATIONSSPEC
ELECTRICAL SPECIFICATIONS
ItemStandardLimit
System voltage12 V



Ignition system
Ignition system type
Ignition timing
Crankshaft position sensor
resistance / color
T.C.I. unit model (manufacturer)
DC. T.C.I.
5 BTDC at 1,050 r / min
336  504 Ω at 20C (68F) / Gy-B
F8T822 (MITSUBISHI) (USA)
F8T823 (MITSUBISHI) (CAL)



















Ignition coils
Model (manufacturer)
Minimum ignition spark gap
Primary coil resistance
Secondary coil resistance
F6T558 (MITSUBISHI)
6 mm (0.24 in)
1.19  1.61 Ω at 20C (68F)
8.5  11.5 kΩ at 20C (68F)















Charging system
System type
Model (manufacturer)
Normal output
Stator coil resistance / color
A.C. magneto
F4T850 (MITSUBISHI)
14 V / 560 W at 5,000 r / min
0.14  0.18 Ω at 20C (68F) / W-W















Rectifier / regulator
Regulator type
Model (manufacture)
Semi conductor short circuit
FH011AA (SHINDENGEN)







()
No-load regulated voltage
Rectifier capacity
Withstand voltage
()
14.3  15.1 V
50 A
100 V











Battery
Battery type
Battery voltage / capacity
Specific gravity
Manufacturer
Ten hour rate amperage
YTZ10S
12 V / 8.6 Ah
1.310
YUASA
0.8 A



















Headlight typeHalogen bulb
Bulbs (voltage / wattage
quantity)
Headlight
Auxiliary light
Tail / brake light
Front turn signal light / position light
Rear turn signal light
Licence plate light
Meter light
12 V 55 W
4
12 V 5 W
2
LED
1
12 V 21 W / 5 W
2
12 V 21 W
2
12 V 5 W
1
LED
1



























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2-24
TIGHTENING TORQUESSPEC
NOTE 1:
NOTE 2:
NOTE 3:
ItemThreadTighteningRemarksItemsizeNmm
kgft
lbRemarks
Battery box and frameM670.75.1
Atmospheric pressure sensor and battery box—0.70.070.5
Lean angle cut-off switch and battery box—20.21.4
Foot rest bracket (front) and frameM8282.820
Foot rest bracket (rear) and frameM8282.820
Rear brake master cylinder and foot rest bracketM6181.813
Rear brake hose union boltM10303.022
Sidestand bracket and frameM10636.346
Front wheel axle shaft and boltM14919.166
Rear wheel axle nutM2415015.0109
Front brake caliper and front forkM10353.525
Front brake disc and front wheelM6181.813
Rear brake disc and rear wheelM6303.022
Rear wheel sprocket and drive hubM1010010.072
Brake caliper bleed screwM860.64.3
Front wheel axle pinch boltM8202.014See NOTE 3
1. First, tighten the ring nut to approximately 52 Nm (5.2 m
kg, 38 ft
lb) with a torque wrench, then
loosen the ring nut completely.
2. Retighten the lower ring nut to specification.
Refer to “INSTALLING THE ENGINE” in chapter 5.
1. Insert the front wheel axle from the right side
and tighten it with the flange bolt from the left
side to 91 Nm (9.1 m
kg, 65.8 ft
lb).
2. In the order from the pinch bolt
2
pinch
bolt
1
pinch bolt 2, tighten each bolt to
20 Nm (2.0 m
kg, 14 ft
lb) without perform-
ing temporary tightening.
3. Check that the end face of the axle head and
the end face of the fork side are flush-
mounted. If they are out of alignment, make
sure to fit them by adding the external force
by hand or with a plastic hammer, etc.
If the end face of the axle is not parallel to the
end face of the fork, align them so that one
point of the axle circumference is positioned
on the end face of the fork.
At this stage, it can be accepted if the end
face of the axle becomes partially concave
to the end face of the fork.
4. In the order from the pinch bolt
4
pinch
bolt
3
pinch bolt 4, tighten each bolt to
20 Nm (2.0 m
kg, 14 ft
lb) without perform-
ing temporary tightening.
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2-43
33Throttle body side cap
34Mud guard
35Turn signal light lead
36License plate light lead
37Rear fender rib
38Speed sensor lead
39Rear brake light switch lead
40Rear frame
41Swingarm bracket
42Main fuse lead
43Starting circuit cut-off relay lead
44Turn signal light relay lead
45Starter relay lead
46Main fuse lead (To the battery
positive lead)
47Right handlebar switch lead
17Battery negative lead
18Starter motor lead
19A.C.magneto lead
20Oil level switch lead
21Sidestand switch lead
22Throttle body lead
23Coolant reservoir tank drain hose
24Fuel tank drain hose
25Cover 7
26Radiator fan motor lead (left)
27Radiator fan motor lead (right)
28Wire harness
29Pipe 3
30Frame
31Coolant reservoir tank hose
32Thermo stat assembly breather
hose
CABLE ROUTINGSPEC
1Heat protector
2Crankshaft position sensor lead
3Neutral switch lead
4Ground lead
5Coolant reservoir tank
6Battery positive lead
7Starter relay
8Turn signal relay
9Main fuse
10Lean angle cut-off switch
11Atmospheric pressure sensor
12Tail / brake light lead
13Rear fender
14Seat lock cable
15Anti safety alarm coupler
16Starting circuit cut-off relay
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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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2-45
W Point the tip of the clamp (sur-
plus section) to the rear side of
the vehicle. Fasten the starter
relay lead, turn signal relay lead,
main fuse lead, main fuse lead
(from the battery positive lead)
and starting circuit cut-off relay
lead with a clamp.
X Route each lead under the wire
harness.
Y Fasten the wire harness, battery
negative lead and starter motor
lead with a clamp. Point the tip of
the clamp (excessive part) to the
inside of the vehicle.P Pass the lead through inside of
the battery band.
Q Press on the tip of the clamp af-
ter passing the leads through it.
R Insert the tail / brake light lead to
the rear frame hole.
S Insert the clamp from the vehicle
front to the rear side and fasten
each lead, coupler and onion-
head to the fender rib, and then
point the tip of the clamp (exces-
sive part) to the upper side of the
vehicle.
T Hold down the clamp tips after
passing each lead.U Make sure to position the cou-
pler at the downmost position of
leads. However, the coupler
should be set in the rear frame so
that it is not caught by the seat
bottom, cover and other compo-
nents.
V Point the tip of the clamp (exces-
sive part) to the inside of the ve-
hicle. Fasten the wire harness
with a clamp.
CABLE ROUTINGSPEC
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2-46
DD Fasten the wire harness,
A.C.magneto lead, and
throttle body lead with a
clamp. 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 ve-
hicle.
EE To the air filter
FF To the throttle body
GG To install the cover 7, install so
as to set each coupler in the
cover. Make sure that each
lead is not caught by the cover
7.Z Point the tip of the clamp (exces-
sive part) to the down side of the
vehicle. Fasten the wire har-
ness, battery negative lead, A.C.
magneto lead and starter motor
lead with a clamp.
AA To the speed sensor
BB Insert the wire harness wrap-
ping clamp to the hole of the
frame.
CC After passing the lead be-
tween the wire harness and
starter motor leads, fastening
by the clamp should be can-
celled and route the lead un-
der the idle remote controller.
CABLE ROUTINGSPEC
HH Insert the wire harness wrap-
ping clamp to the hole of the
frame.
II Make sure that the lead is fas-
tened with the guide of the ra-
diator stay.
JJ To the right handlebar switch
KK Do not place it beyond pipe 3
in the direction to the external
part of the vehicle.
LL Battery negative lead should
not run on the swingarm
bracket.
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3-62
CHECKING AND CHARGING THE BATTERY
CHK
ADJ
WARNING
CAUTION:
EAS00178
ELECTRICAL SYSTEM
CHECKING AND CHARGING THE BATTERY
Batteries generate explosive hydrogen gas
and contain electrolyte which is made of poi-
sonous and highly caustic sulfuric acid.
Therefore, always follow these preventive
measures:

Wear protective eye gear when handling or
working near batteries.

Charge batteries in a well-ventilated area.

Keep batteries away from fire, sparks or
open flames (e.g., welding equipment,
lighted cigarettes).

DO NOT SMOKE when charging or han-
dling batteries.

KEEP BATTERIES AND ELECTROLYTE
OUT OF REACH OF CHILDREN.

Avoid bodily contact with electrolyte as it
can cause severe burns or permanent eye
injury.
FIRST AID IN CASE OF BODILY CONTACT:
EXTERNAL

Skin – Wash with water.

Eyes – Flush with water for 15 minutes and
get immediate medical attention.
INTERNAL

Drink large quantities of water or milk fol-
lowed with milk of magnesia, beaten egg or
vegetable oil. Get immediate medical atten-
tion.

This is a sealed battery. Never remove the
sealing caps because the balance between
cells will not be maintained and battery per-
formance will deteriorate.

Charging time, charging amperage and
charging voltage for an MF battery are dif-
ferent from those of conventional batter-
ies. The MF battery should be charged as
explained in the charging method illustra-
tions. If the battery is overcharged, the
electrolyte level will drop considerably.
Therefore, take special care when charging
the battery.
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3-63
Relationship between the open-circuit voltage
and the charging time at 20C
Open-circuit voltage (V)
These values vary with the temperature, the condition of
the battery plates, and the electrolyte level. 13.0
12.5
12.0
11.5
5 6.5 10
Charging time (hours)
Ambient
temperature
20C
Open-circuit voltage (V)
Charging condition of the battery (%)
CHECKING AND CHARGING THE BATTERY
CHK
ADJ
NOTE:
CAUTION:
NOTE:
Since MF batteries are sealed, it is not possible
to check the charge state of the battery by mea-
suring the specific gravity of the electrolyte.
Therefore, the charge of the battery has to be
checked by measuring the voltage at the battery
terminals.
1. Remove:

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

battery leads
(from the battery terminals)
First, disconnect the negative battery lead
1, and then the positive battery lead 2.
3. Remove:

battery
4. Check:

battery charge
a. Connect a pocket tester to the battery termi-
nals.
Pocket tester
90890-03112, YU-3112
Positive tester probe

positive battery terminal
Negative tester probe

negative battery terminal

The charge state of an MF battery can be
checked by measuring its open-circuit voltage
(i.e., the voltage when the positive battery ter-
minal is disconnected).

No charging is necessary when the open-cir-
cuit voltage equals or exceeds 12.8 V.
b. Check the charge of the battery, as shown in
the charts and the following example.
Example
c. Open-circuit voltage = 12.0 V
d. Charging time = 6.5 hours
e. Charge of the battery = 20
30%
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3-64
Charging
Ambient temperature 20C
Open-circuit voltage (V)
Check the open-circuit
voltage.Time (minutes)
CHECKING AND CHARGING THE BATTERY
CHK
ADJ
WARNING
CAUTION:
5. Charge:

battery
(refer to the appropriate charging method il-
lustration)
Do not quick charge a battery.

Never remove the MF battery sealing caps.

Do not use a high-rate battery charger
since it forces a high-amperage current
into the battery quickly and can cause bat-
tery overheating and battery plate damage.

If it is impossible to regulate the charging
current on the battery charger, be careful
not to overcharge the battery.

When charging a battery, be sure to remove
it from the motorcycle. (If charging has to
be done with the battery mounted on the
motorcycle, disconnect the negative bat-
tery lead from the battery terminal.)

To reduce the chance of sparks, do not
plug in the battery charger until the battery
charger leads are connected to the battery.

Before removing the battery charger lead
clips from the battery terminals, be sure to
turn off the battery charger.

Make sure the battery charger lead clips
are in full contact with the battery terminal
and that they are not shorted. A corroded
battery charger lead clip may generate heat
in the contact area and a weak clip spring
may cause sparks.

If the battery becomes hot to the touch at
any time during the charging process, dis-
connect the battery charger and let the bat-
tery cool before reconnecting it. Hot batter-
ies can explode!

As shown in the following illustration, the
open-circuit voltage of an MF battery stabi-
lizes about 30 minutes after charging has
been completed. Therefore, wait 30 min-
utes after charging is completed before
measuring the open-circuit voltage.
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