engine YAMAHA YZF-R1SC 2004 Owner's Manual

2-8
ENGINE SPECIFICATIONSSPEC
ItemStandardLimit
Connecting rods
Crankshaft-pin-to-big-end-bearing
clearance
Bearing color code
0.034  0.058 mm (0.0013  0.0023 in)
1 = Blue 2 = Black 3 = Brown 4 = Green0.09 mm
(0.0035 in)




Crankshaft
Width A
Width B
Max. runout C
Big end side clearance D
Crankshaft-journal-to-crankshaft-
journal-bearing clearance
Bearing color code
55.20  56.60 mm (2.17  2.23 in)
298.8  300.7 mm (11.76  11.84 in)




0.160  0.262 mm (0.0063  0.0103 in)
0.014  0.037 mm (0.0006  0.0015 in)
0 = White 1 = Blue 2 = Black
3 = Brown 4 = Green







0.03 mm
(0.0012 in)




0.10 mm
(0.0039 in)




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2-9
ENGINE SPECIFICATIONSSPEC
ItemStandardLimit
Clutch
Clutch type
Clutch release method
Clutch release method operation
Operation
Clutch cable free play (at the end
of the clutch lever)
Friction plates
Color code
Thickness
Plate quantity
Color code
Thickness
Plate quantity
Color code
Thickness
Plate quantity
Clutch plates
Thickness
Plate quantity
Max. warpage
Clutch springs
Free length
Spring quantity
Wet, multiple disc
Outer pull, rack and pinion pull
Cable operation
Left-hand operation
10  15 mm (0.39  0.59 in)
Purple
2.9  3.1 mm (0.114  0.122 in)
7
Green
2.9  3.1 mm (0.114  0.112 in)
1
–
2.9  3.1 mm (0.114  0.112 in)
1
1.9  2.1 mm (0.07  0.08 in)
8




52.5 mm (2.07 in)
6























2.8 mm
(0.110 in)








2.8 mm
(0.110 in)








2.8 mm
(0.110 in)












0.1 mm
(0.0039 in)
49.9 mm
(1.96 in)




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2-10
ENGINE SPECIFICATIONSSPEC
ItemStandardLimit
Transmission
Transmission type
Primary reduction system
Primary reduction ratio
Secondary reduction system
Secondary reduction ratio
Operation
Gear ratios
1st gear
2nd gear
3rd gear
4nd gear
5th gear
6th gear
Max. main axle runout
Max. drive axle runout
Constant mesh, 6-speed
Spur gear
65 / 43 (1.512)
Chain drive
45 / 17 (2.647)
Left-foot operation
38 / 15 (2.533)
33 / 16 (2.063)
37 / 21 (1.762)
35 / 23 (1.522)
30 / 22 (1.364)
33 / 26 (1.269)























































0.08 mm
(0.0032 in)
0.08 mm
(0.0032 in)
Shifting mechanism
Shift mechanism type
Max. shift fork guide bar bending
Shift drum / Guide bar







0.10 mm
(0.0039 in)
Air filter typeOil coated paper element



Fuel pump
Pump type
Model (manufacturer)
Output pressure
Electrical
5PW (DENSO)
294 kPa (2.94 kg / cm
2, 2.94 bar, 42.6 psi)












Throttle position sensor
Resistance
Output voltage (at idle)
4.9  5.1 kΩ at 20C (68F)
0.63  0.73 V



Throttle bodies
Model (manufacturer)
quantity
Intake vacuum pressure
Throttle cable free play (at the flange
45EIDW (MIKUNI)
2
22 kPa (165 mmHg, 6.4966 inHg)
3  5 mm (0.12  0.20 in)











of the throttle grip)
ID mark
Throttle valve size
5VY1 00 (USA)
5VY5 10 (CAL)
#100







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2-16
ELECTRICAL SPECIFICATIONSSPEC
ItemStandardLimit
Indicator light
(voltage / wattage
quantity)
Neutral indicator light
High beam indicator light
Oil level warning light
Turn signal indicator light
Fuel level warning light
Coolant temparture indicator light
Engine trouble warning light
Shift timing indicator light
LED
1
LED
1
LED
1
LED
2
LED
1
LED
1
LED
1
LED
1































Electric starting system
System type
Starter motor
Model (manufacturer)
Power output
Brushes
Overall length
Spring force
Armature coil resistance
Commutator diameter
Mica undercut
Constant mesh
5VY (YAMAHA)
0.9 kW
10.8 mm (0.43 in)
5.28  7.92 N (538  808 g,
18.99  28.48 oz)
0.0090  0.0110 Ω at 20C (68F)
24.5 mm (0.96 in)
1.5 mm (0.06 in)











3.6 mm
(0.14 in)








23.5 mm
(0.93 in)




Starter relay
Model (manufacturer)
Amperage
Coil resistance
2768079-A (JIDECO)
180 A
4.18  4.62 Ω at 20C (68F)











Horn
Horn type
Model (manufacturer)
quantity
Max. amperage
Performance
Coil resistance
Plane
YF-12 (NIKKO)
1
3 A
105  113 db / 2 m
1.15  1.25 Ω at 20C (68F)



















Turn signal relay
Relay type
Model (manufacturer)
Self-cancelling device built-in
Turn signal blinking frequency
Wattage
Full transistor
FE218BH (DENSO)
No
75  95 cycles / min.
21 W
2 + 3.4 W



















Oil level switch
Model (manufacturer)
5VY (SOMIC ISHIKAWA)



EXUP servo motor
Model (manufacturer)
5VY (YAMAHA)



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2-19
TIGHTENING TORQUESSPEC
Use a lock
washer
TIGHTENING TORQUES
ENGINE TIGHTENING TORQUES
ItemFastenerThreadQ’tyTightening torqueRemarksItemFastenersizeQtyNmm
kgft
lbRemarks
Spark plugs—M104131.39.4
Cylinder headNutM1010See NOTE 1
BoltM62121.28.7
Camshaft capsBoltM628101.07.2
Cylinder head coverBoltM66121.28.7
Cylinder head (exhaust pipe)Stud boltM88151.511
Air indication system capBoltM64101.07.2
Camshaft sprocketsBoltM74242.417
Cylinder head and throttle bodyClampM5430.32.2
Connecting rod capsBoltM8820+1502.0+15014+150
Generator rotorBoltM101606.043
Timing chain tensionerBoltM62101.07.2
Water pump outlet pipeBoltM61101.07.2
Water pump inlet pipeBoltM61101.07.2
(water pump side)
Water pump inlet pipe (front side)BoltM61101.07.2
Oil / water pump assembly
sprocketBoltM61151.511
Water pumpBoltM62121.28.7
Thermostat coverNutM62101.07.2
Thermostat inlet pipeBoltM61101.07.2
Oil coolerBoltM201636.346
Engine oil drain boltBoltM141434.331
Oil pipeBoltM62101.07.2
Oil strainerBoltM63101.07.2
Oil delivery pipeBoltM63101.07.2
Oil filter union boltBoltM201707.051
Oil filter—M201171.712
Oil panBoltM614121.28.7
Oil panBoltM61121.28.7
Air filter case coverScrewM5101.70.171.2
Throttle body and throttle body
jointClampM5430.32.2
Throttle body and funnelBoltM564.20.423.0
Throttle cableNutM614.50.453.3
Throttle cable adjusterBoltM614.50.453.3
Stator coilScrewM63141.410
Generator rotor cover and
bearing housingScrewM63101.07.2
Pull lever coverBoltM62101.07.2
Thermostat assembly stayBoltM62101.07.2
Starter clutch idler gearBoltM61101.07.2
Clutch bossNutM201959.569Stake
Clutch springBoltM66101.07.2
Drive sprocketNutM221858.561
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2-23
TIGHTENING TORQUESSPEC
See NOTE 2 CHASSIS TIGHTENING TORQUES
ItemThreadTighteningRemarksItemsizeNmm
kgft
lbRemarks
Upper bracket and outer tubeM8262.619
Upper bracket and steering stem nutM2811 311.382
Handlebar and outer tubeM8171.712
Handlebar and upper bracketM6131.39
Steering shaft and ring nutM30181.813See NOTE 1
Outer tube and under bracketM8232.317
Main switch and upper bracketM8262.619
Front brake master cylinder cap stopperM41.20.120.9
Front brake hose union boltsM10303.022
Front brake master cylinder and bracketM6131.39
Meter assembly and front cowling stay—1.30.130.9
Headlight and front cowling stay—0.80.080.6
Front cowling and headlight assembly—1.50.151.1
Cover 7, 8 and frameM650.53.6
Under cowling and engineM650.53.6
Windshield and front cowlingM50.40.040.3
Duct and console panelM51.30.130.9
End grip and handlebarM640.42.9
Horn bracket and under bracketM640.42.9
Coolant reservoir tank and frameM650.53.6
Engine mount front (left and right)M10454.533
Engine mount rear upperM10515.137
Engine mount rear underM10515.137
Engine mount rear adjust boltM1670.75.1
Catalyst pipe stay and frameM10444.432
Clutch cable lock nut (engine side)M870.75.1
Main frame and rear frameM10414.130
Throttle cable adjust nut (throttle body side)M650.53.6
Cover 2 and plate—0.80.080.6
Pivot shaft and nutM1810510.576
Connecting rod and frameM10444.432
Relay arm and connecting rodM10444.432
Relay arm and swingarmM10444.432
Rear shock absorber and relay armM10444.432
Rear shock absorber and upper bracketM10444.432
Upper bracket and frameM14929.267
Seal guardM670.75.1
Drive chain caseM670.75.1
Chain puller adjust nutM8161.612
Fuel tank and fuel pump assemblyM540.42.9
Fuel tank stay (front side) and frameM670.75.1
Fuel tank and fuel tank stay (front side)M670.75.1
Fuel tank stay (rear side) and rear frameM670.75.1
Side cover and fuel tankM50.40.040.3
Rider seat and frameM670.75.1
Seat lock plate and rear frameM6101.07
Side cover (rear side) and frameM540.42.9
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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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2-25
LUBRICATION POINTS AND LUBRICANT TYPESSPEC
EAS00031
LUBRICATION POINTS AND LUBRICANT TYPES
ENGINE
Lubrication point
Lubricant
Oil seal lips
O-rings
Bearings
Crankshaft pins
Piston surfaces
Piston pins
Crankshaft journals
Camshaft lobes
Camshaft journals
Valve stems (intake and exhaust)
Valve stem ends (intake and exhaust)
Water pump impeller shaft
Oil pump rotors (inner and outer)
Oil pump housing
Oil strainer
Clutch (pull rod)
Oil / water pump drive sprocket and washer
Clutch (thrust plate)
Starter clutch idle gear inner surface
Starter clutch assembly
Primary driven gear
Transmission gears (wheel and pinion)
Main axle and drive axle
Shift drum
Shift forks and shift fork guide bars
Shift shaft
Shift shaft boss
Cylinder head cover mating surfaceYamaha bond
No.1215
Crankcase mating surfaceYamaha bond
No.1215
Clutch cover (crankcase mating surface)Yamaha bond
No.1215
Generator rotor cover (crankcase mating surface)Yamaha bond
No.1215
Pickup rotor coverYamaha bond
No.1215
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2-26
LUBRICATION POINTS AND LUBRICANT TYPESSPEC
EAS00032
CHASSIS
Lubrication point
Lubricant
Steering bearings and bearing races (upper and lower)
Throttle grip inner surface
Brake lever pivoting point and metal-to-metal moving parts
Clutch lever pivoting point and metal-to-metal moving parts
Engine mount bolts (rear upper and lower)
Relay arm, connecting rod and rear shock absorber collar
Pivot shaft
Swingarm pivot bearing
Swingarm head pipe end, oil seal and bush
Oil seal (relay arm, connecting arm and rear shock absorber)
Seat lock assembly moving parts
Sidestand pivoting pint and metal-to-metal moving parts
Link and sidestand switch contact point
Sidestand hook and spring
Shift shaft joint
Front wheel oil seal (right and left)
Front axle shaft
Rear wheel oil seal
Rear wheel drive hub oil seal
Rear wheel drive hub mating surface
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2-29
ENGINE OIL LUBRICATION CHARTSPEC
ENGINE OIL LUBRICATION CHART
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