seats YAMAHA YZF-R1SC 2004 User Guide
[x] Cancel search | Manufacturer: YAMAHA, Model Year: 2004, Model line: YZF-R1SC, Model: YAMAHA YZF-R1SC 2004Pages: 457, PDF Size: 7.58 MB
Page 96 of 457
3-19
SYNCHRONIZING THE THROTTLE BODIES /
ADJUSTING THE EXHAUST GAS VOLUMECHK
ADJ
NOTE:
NOTE: 9. Measure:
engine idling speed
Out of specification Adjust.
Make sure that the vacuum pressure is within
specification.
10. Stop the engine and remove the measuring
equipment.
11. Adjust:
throttle cable free play
Refer to “ADJUSTING THE THROTTLE
CABLE FREE PLAY”.
Throttle cable free play
(at the flange of the throttle grip)
3 5 mm (0.12 0.20 in)
13. Install:
synchronizing hoses
fuel tank
Refer to “FUEL TANK”.
rider seat
Refer to “SEATS”.
ADJUSTING THE EXHAUST GAS VOLUME
Be sure to set the carbon monoxide density to
standard, and then adjust the exhaust gas.
1. Turn the main switch to “OFF” and engine
stop switch “ON”.
2. While keeping the “SELECT” and “RESET”
buttons pressed simultaneously, turn “ON”
the main switch (keep them pressed for 8 se-
conds or more).
All indications on the meter disappear except
the clock and trip indications.
Letters “dIAG” appear on the clock LCD.
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Page 109 of 457
3-32
ADJUSTING THE CLUTCH CABLE FREE PLAY /
REPLACING THE AIR FILTER ELEMENTCHK
ADJ
a
b
NOTE: Engine side
a. Loosen the locknut
1.
b. Turn the adjusting nut
2 in direction a or b
until the specified clutch cable free play is ob-
tained.
Direction
Clutch cable free play is
increased.
DirectionClutch cable free play is
decreased.
c. Tighten the locknuts.
Lock nut
7Nm (0.7 mkg, 5.1 ftlb)
EAS00086
REPLACING THE AIR FILTER ELEMENT
1. Remove:
rider seat
Refer to “SEATS”.
fuel tank
Refer to “FUEL TANK”.
2. Remove:
air filter case cover
1
3. Check:
air filter element
1
Damage Replace.
Replace the air filter element at periodic inter-
vals of 40,000 km travel.
The air filter needs more frequent service if you
are riding in unusuallu wet or dusty areas.
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Page 110 of 457
3-33
REPLACING THE AIR FILTER ELEMENT /
CHECKING THE FUEL AND BREATHER HOSESCHK
ADJ
CAUTION:
NOTE:
NOTE: 4. Install:
air filter case cover
Never operate the engine without the air fil-
ter element installed. Unfiltered air will
cause rapid wear of engine parts and may
damage the engine. Operating the engine
without the air filter element will also affect
the throttle bodies tuning, leading to poor
engine performance and possible overheat-
ing.
When installing the air filter element into the air
filter case cover, make sure their sealing sur-
faces are aligned to prevent any air leaks.
5. Install:
fuel tank
Refer to “FUEL TANK”.
rider seat
Refer to “SEATS”.
EAS00096
CHECKING THE FUEL AND BREATHER
HOSES
The following procedure applies to all of the fuel
and breather hoses.
1. Remove:
rider seat
Refer to “SEATS”.
fuel tank
Refer to “FUEL TANK”.
2. Check:
breather hose
1
fuel hose 2
Cracks / damage Replace.
Loose connection Connect properly.
Before removing the fuel hoses, place a few
rags in the area under where it will be removed.
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Page 111 of 457
3-34
CHECKING THE FUEL AND BREATHER HOSES /
CHECKING THE CRANKCASE BREATHER HOSECHK
ADJ
CAUTION:
CAUTION:
CAUTION:
3. Install:
fuel tank
Refer to “FUEL TANK”.
rider seat
Refer to “SEATS”.
To install the fuel tank, check that the breath-
er hose is not folded or pinched by the fuel
tank.
EAS00098
CHECKING THE CRANKCASE BREATHER
HOSE
1. Remove:
rider seat
Refer to “SEATS”.
fuel tank
Refer to “FUEL TANK”.
2. Check:
crankcase breather hose
1
Cracks / damage Replace.
Loose connection Connect properly.
Make sure the crankcase breather hose is
routed correctly.
3. Install:
fuel tank
Refer to “FUEL TANK”.
rider seat
Refer to “SEATS”.
To install the fuel tank, check that the breath-
er hose is not folded or pinched by the fuel
tank.
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Page 116 of 457
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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Page 118 of 457
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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Page 140 of 457
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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Page 144 of 457
3-67
CHECKING AND CHARGING THE BATTERY /
CHECKING THE FUSESCHK
ADJ
CAUTION:
CAUTION:
NOTE: 6. Install:
battery
7. Connect:
battery leads
(to the battery terminals)
First, connect the positive battery lead
1,
and then the negative battery lead
2.
8. Check:
battery terminals
Dirt Clean with a wire brush.
Loose connection Connect properly.
9. Lubricate:
battery terminals
Recommended lubricant
Dielectric grease
10. Install:
rider seat
Refer to “SEATS”.
EAS00181
CHECKING THE FUSES
The following procedure applies to all of the
fuses.
To avoid a short circuit, always set the main
switch to “OFF” when checking or replacing
a fuse.
1. Remove:
front cowling inner panel (left)
Refer to “COWLINGS”.
rider seat
Refer to “SEATS”.
2. Check:
fuse
a. Connect the pocket tester to the fuse and
check the continuity.
Set the pocket tester selector to “Ω 1”.
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Page 145 of 457
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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Page 224 of 457
5-2
5
Order Job / Part Q’ty Remarks
1
2
3
4
5
6
7
8
9
10Removing the exhaust pipe
Rider seat and passenger seat
Fuel tank
Side cowlings and bottom cowlings
EXUP pulley cover
EXUP cable
Exhaust pipe assembly
Exhaust pipe gasket
Exhaust valve pipe gasket
Exhaust valve pipe assembly
Catalyst pipe assembly
Gasket
Muffler
Gasket1
2
1
4
1
1
1
1
2
2Remove the parts in the order listed.
Refer to “SEATS” in chapter 3.
Refer to “FUEL TANK” in chapter 3.
Refer to “COWLINGS” in chapter 3.
10 Nm (1.0 mkg, 7.2 ftlb)
10 Nm (1.0 mkg, 7.2 ftlb)
10 Nm (1.0 mkg, 7.2 ftlb)
20 Nm (2.0 mkg, 14 ftlb)
20 Nm (2.0 mkg, 14 ftlb)
20 Nm (2.0 mkg, 14 ftlb)
23 Nm (2.3 mkg, 17 ftlb)
ENGINEENG
EXHAUST PIPE
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