fuel YAMAHA YZF-R1SC 2004 Owner's Manual

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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2-48
a Fuel piping connector attach-
ment directions. (fuel pump side)
1. Insert the connector until the
click sound is heard and check
that the connector does not
come off. Make sure that no for-
eign matter is caught in the seal-
ing section. (It is prohibited to
wear the cotton work gloves or
equivalent coverings.)
G This part works as a dropout
stopper.
2. After Item 1 mentioned above is
finished, check that the clamp is
inserted from the down side, and
, and -sections are per-
fectly equipped.
ABC
A Install the lip of O-ring facing up-
ward.
B Install the part pointing the white
paint part of the hose to the left
side of the vehicle.
C Any direction of the clip grip can
be accepted.
D Install the clip grip as specified in
the drawing.
E Install the part pointing the white
paint part of the hose to the left
side of the vehicle.
F Point the clip grip to the left side
of the vehicle.
CABLE ROUTINGSPEC
1Fuel tank
2O-ring
3Fuel tank drain hose
4Fuel tank breather hose
5Clip
6Air filter stay
7Fuel hose 2
83 way connector
9Pipe
10Fuel tank bracket
11Fuel hose clamp
12Fuel hose 1
13Fuel pump assembly
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3-1
3
INTRODUCTION / PERIODIC MAINTENANCE CHART FOR THE EMISSION
CONTROL SYSTEM / GENERAL MAINTENANCE AND LUBRICATION CHARTCHK
ADJ
EAS00036
PERIODIC CHECKS AND ADJUSTMENTS
INTRODUCTION
This chapter includes all information necessary to perform recommended checks and adjustments. If
followed, these preventive maintenance procedures will ensure more reliable vehicle operation, a
longer service life and reduce the need for costly overhaul work. This information applies to vehicles
already in service as well as to new vehicles that are being prepared for sale, All service technicians
should be familiar with this entire chapter.
PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM
INITIALODOMETER READINGS
No.ITEMROUTINE600 mi
(1000 km)
or
1 month4000 mi
(7000 km)
or
6 months8000 mi
(13000 km)
or
12 months12000 mi
(19000 km)
or
18 months16000 mi
(25000 km)
or
24 months20000 mi
(31000 km)
or
30 months
1*Fuel line
(See page 3-33)
Check fuel hoses for cracks or damage.

Replace if necessary.





2*Spark plugs
(See page 3-23)
Check Condition.

Adjust gap and clean.

Replace every 8000 mi (13000 km) or 12
months.
Replace.
Replace.

3*Valve clearance
(See page 3-11)
Check and adjust valve clearance when en-
gine is cold.Every 26600 mi (42000 km)
4*Crankcase breather
system
(See page 3-34)
Check breather hose for cracks or damage.

Replace if necessary.





5*Electronic fuel injection
(See page 3-17, 21)
Check and adjust engine idle speed and syn-
chronization.






6*Exhaust system
(See page 3-35)
Check for leakage.

Tighten if necessary.

Replace gasket(s) if necessary.





7*Evaporative emission
control system
(For California only)
Check control system for damage.

Replace if necessary.


8*Air induction system
(See page 7-46)
Check the air cut-off valve, reed valve, and
hose for damage.

Replace any damaged parts if necessary.


GENERAL MAINTENANCE AND LUBRICATION CHART
INITIALODOMETER READINGS
No.ITEMROUTINE600 mi
(1000 km)
or
1 month4000 mi
(7000 km)
or
6 months8000 mi
(13000 km)
or
12 months12000 mi
(19000 km)
or
18 months16000 mi
(25000 km)
or
24 months20000 mi
(31000 km)
or
30 months
1*Air filter element
(See page 3-32)
Check condition and damage.
Replace if necessary.





2*Clutch
(See page 3-31)
Check operation.
Adjust or replace cable.






3*Front brake
(See page 3-42, 44, 45)
Check operation, fluid level, and for fluid leak-
age.

Replace brake pads if necessary.






4*Rear brake
(See page 3-43, 44, 45)
Check operation, fluid level, and for fluid leak-
age.

Replace brake pads if necessary.






5*Brake hoses
Check for cracks or damage.




5*Brake hoses(See page 3-46)
Replace.Every 4 years
6*Wheels
(See page 4-3)
Check runout and for damage.
Replace if necessary.





7*Tires
(See page 3-58)
Check tread depth and for damage.
Replace if necessary.
Check air pressure.
Correct if necessary.






8*Wheel bearings
(See page 4-3)
Check bearings for smooth operation.
Replace if necessary.





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3-4
Order Job / Part Q’ty Remarks
1
2
3
4
5
6
7
8
9
10
11Removing the fuel tank
Rider sear
Fuel tank side cover
Fuel hose connector cover
Fuel hose
Fuel return hose
Fuel sender coupler
Fuel pump coupler
Fuel tank over flow hose
Fuel tank breather hose
Fuel tank
Fuel tank cover
Fuel pump2
1
1
1
1
1
1
1
1
1
1Remove the parts in the order listed.
Refer to “SEATS”.
Disconnect.
Disconnect.
Disconnect.
Disconnect.
Disconnect.
Disconnect.
Disconnect.
For installation, reverse the removal
procedure.
10 Nm (1.0 m
kg, 7.2 ft
lb)
10 Nm (1.0 m
kg, 7.2 ft
lb)
4 Nm (0.4 m
kg, 2.9 ft
lb)
4 Nm (0.4 m
kg, 2.9 ft
lb)
FUEL TANK
CHK
ADJ
EAS00040
FUEL TANK
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3-5
FUEL TANK
CHK
ADJ
CAUTION:
NOTE:
NOTE:
CAUTION:
REMOVING THE FUEL TANK
1. Extract the fuel in the fuel tank through the
fuel tank cap with a pump.
2. Remove:

fuel hose connector cover

fuel return hose

fuel hose

fuel sender coupler

fuel pump coupler

fuel tank breather hose

fuel tank over flow hose
Although the fuel has been removed from
the fuel tank, be careful when removing the
fuel hoses, since there may be fuel remain-
ing in it.
Before removing the hoses, place a few rags in
the area under where it will be removed.
3. Remove:

fuel tank
Do not set the fuel tank down so that the installa-
tion surface of the fuel pump is directly under the
tank. Be sure to lean the fuel tank in an upright
position.
REMOVING THE FUEL PUMP
1. Remove:

fuel pump

Do not drop the fuel pump or give it a
strong shock.

Do not touch the base section of the fuel
sender.
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3-6
FUEL TANK
CHK
ADJ
4 Nm (0.4 m
kg, 2.9 ft
lb)
NOTE:
CAUTION:
INSTALLING THE FUEL PUMP
1. Install:

fuel pump

Do not damage the installation surfaces of the
fuel tank when installing the fuel pump.

Always use a new fuel pump gasket.

Install the fuel pump as shown in the illustra-
tion.

Tighten the fuel pump bolts in stages in a criss-
cross pattern and to the specified torque.
INSTALLING THE FUEL TANK
1. Install:

fuel hose

fuel return hose

fuel hose connector cover
When installing the fuel hose, make sure
that it is securely connected, and that the
fuel hose holder is in the correct position,
otherwise the fuel hose will not be properly
installed.
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3-10
Order Job / Part Q’ty Remarks
1
2
3
4
5
6
7
8
9
10Removing the air filter case
Rider sear
Fuel tank
Plug
Air temperature sensor lead coupler
Spacer
Air temperature sensor
Air filter case cover
Air filter
Funnel
Air filter case
Air induction system hose
Crankcase breather hose1
1
1
1
1
1
2
1
1
1Remove the parts in the order listed.
Refer to “SEATS”.
Refer to “FUEL TANK”.
Disconnect.
Disconnect.
Disconnect.
For installation, reverse the removal
procedure.
2 Nm (0.2 m
kg, 1.4 ft
lb)
3.4 Nm (0.34 m
kg, 2.5 ft
lb)
AIR FILTER CASE
CHK
ADJ
AIR FILTER CASE
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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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3-17
ADJUSTING THE VALVE CLEARANCE /
SYNCHRONIZING THE THROTTLE BODIESCHK
ADJ
NOTE:
NOTE:
NOTE:
7. Install:

all removed parts
For installation, reverse the removal procedure.
SYNCHRONIZING THE THROTTLE BODIES
Prior to synchronizing the throttle bodies, the
valve clearance and the engine idling speed
should be properly adjusted and the ignition tim-
ing should be checked.
1. Stand the motorcycle on a level surface.
Place the motorcycle on a suitable stand.
2. Remove:

rider seat
Refer to “SEATS”.

fuel tank
Refer to “FUEL TANK”.
3. Remove:

synchronizing hoses
1
4. Install:

vacuum gauge
1
(onto the synchronizing hose)

digital tachometer
(near the spark plug)
Vacuum gauge
90890-03094, YU-08030
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3-18
SYNCHRONIZING THE THROTTLE BODIES
CHK
ADJ
NOTE:
CAUTION:
NOTE: 5. Install:

fuel tank
Refer to “FUEL TANK”.
6. Start the engine and let it warm up for several
minutes.
7. Measure:

engine idling speed
Out of specification
Adjust.
Refer to “ADJUSTING THE ENGINE IDLING
SPEED”.
Engine idling speed
1,150  1,250 r / min
8. Adjust:

throttle body synchronization
a. With throttle body #3 as standard, adjust
throttle bodies #1, #2, and #4 using the air
screws
1.

After each step, rev the engine two or three
times, each time for less than a second, and
check the synchronization again.

If the air screw is removed, turn the screw 3 / 4
turn in and be sure to synchronize the throttle
body.
Do not use the throttle valve adjusting
screws to adjust the throttle body synchro-
nization.
Vacuum pressure at engine
idling speed
22 kPa
(165 mmHg, 6.5 inHg)
The difference in vacuum pressure between
two throttle bodies should not exceed 1.33 kPa
(10 mmHg, 0.39 inHg).
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