wheel YAMAHA YZF-R1SC 2004 Owner's Guide

4-61
Order Job / Part Q’ty Remarks
1
2
3
4
5
6
7
8
9
10Removing the under bracket
Front wheel
Front cowling and side cowling
Front fork legs
Main switch connector
Upper bracket bolt
Left handlebar assembly
Right handlebar assembly
Steering stem nut
Upper bracket
Under bracket panel
Brake hose holder bolt
Lock washer
Upper ring nut2
2
1
1
1
1
1
1
1
1Remove the parts in the order listed.
Refer to “FRONT WHEEL AND BRAKE
DISCS”.
Refer to “COWLINGS” in chapter 3.
Refer to “FRONT FORK”.
Disconnect.
For installation, reverse the removal
procedure.
38 Nm (0.38 m
kg, 2.75 ft
lb)113 Nm (11.3 m
kg, 82 ft
lb)
52 Nm (5.2 m
kg, 38 ft
lb)
18 Nm (1.8 m
kg, 13 ft
lb)
1st
2nd23 Nm (2.3 m
kg, 17 ft
lb)
23 Nm (2.3 m
kg, 17 ft
lb)
7 Nm (0.7 m
kg, 5.1 ft
lb)
17 Nm (1.7 m
kg, 12 ft
lb)
STEERING HEADCHAS
EAS00676
STEERING HEAD
UNDER BRACKET
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4-67
REAR SHOCK ABSORBER ASSEMBLYCHAS
WARNING
NOTE:
NOTE:
NOTE:
EAS00690
REMOVING THE REAR SHOCK ABSORBER
ASSEMBLY
1. Stand the motorcycle on a level surface.
Becurely support the motorcycle so that
there is no danger of it falling over.
Place the motorcycle on a suitable stand so that
the rear wheel is elevated.
2. Remove:

bottom cowling
Refer to “COWLINGS” in chapter 3.

servo motor
Refer to “EXHAUST PIPE” in chapter 5.
3. Remove:

rear shock absorber assembly lower bolt
1

relay arm-to-swingarm bolt 2
While removing the rear shock absorber as-
sembly lower bolt, hold the swingarm so that it
does not drop down.
4. Remove:

rear shock absorber assembly upper bolt
1

rear shock absorber assembly
Raise the swingarm and then remove the rear
shock absorber assembly from between the
swingarm.
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4-69
SWINGARM AND DRIVE CHAINCHAS
Order Job / Part Q’ty Remarks
1
2
3
4
5
6
7Removing the swingarm and drive
chain
Rear wheel
Rear shock absorber
Drive sprocket
Muffler
Catalyst pipe assembly
Right footrest bracket
Adjusting bolt / locknut
Drive chain guard
Rear fender
Brake hose holder
Pivot shaft nut / washer
Pivot shaft1
2/2
1
1
1
1/1
1Remove the parts in the order listed.
Refer to “REAR WHEEL AND BRAKE
DISC”.
Refer to “REAR SHOCK ABSORBER
ASSEMBLY”.
Refer to “ENGINE REMOVAL” in chapter
5.
Refer to “EXHAUST PIPE” in chapter 5.
Refer to “EXHAUST PIPE” in chapter 5.
28 Nm (2.8 m
kg, 20 ft
lb)
7 Nm (0.7 m
kg, 5.1 ft
lb)
7 Nm (0.7 m
kg, 5.1 ft
lb)
105 Nm (10.5 m
kg, 76 ft
lb)
2 Nm (0.2 m
kg, 1.4 ft
lb)
16 Nm (1.6 m
kg, 12 ft
lb)
EAS00700
SWINGARM AND DRIVE CHAIN
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4-71
SWINGARM AND DRIVE CHAINCHAS
WARNING
NOTE:
NOTE:
EAS00703
REMOVING THE SWINGARM
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 rear wheel is elevated.
2. Remove:

relay arm-to-swingarm bolt
1

connecting arm bolt 2

rear shock absorber assembly lower bolt 3
When removing the rear shock absorber as-
sembly lower bolt, hold the swingarm so that it
does not drop down.
3. Measure:

swingarm side play

swingarm vertical movement
a. Measure the tightening torque of the pivot
shaft nut.
Pivot shaft nut
105 Nm (10.5 m
kg, 76 ft
lb)
b. Measure the swingarm side play
A by mov-
ing the swingarm from side to side.
c. If the swingarm side play is out of specifica-
tion, check the spacers, bearings, washers,
and dust covers.
Swingarm side play
(at the end of the swingarm)
1.0 mm (0.04 in)
d. Check the swingarm vertical movement
B
by moving the swingarm up and down.
If swingarm vertical movement is not smooth
or if there is binding, check the spacers,
bearings, washers, and dust covers.
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4-72
SWINGARM AND DRIVE CHAINCHAS
WARNING
NOTE:
NOTE:
WARNING
EAS00704
REMOVING THE DRIVE CHAIN
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 rear wheel is elevated.
2. Remove:

drive chain
(with the drive chain cutter)
Only cut the drive chain if it or the swingarm is to
be replaced.
EAS00707
CHECKING THE SWINGARM
1. Check:

swingarm
Bends / cracks / damage
Replace.
2. Check:

pivot shaft
Roll the pivot shaft on a flat surface.
Bends
Replace.
Do not attempt to straighten a bent pivot
shaft.
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4-75
SWINGARM AND DRIVE CHAINCHAS
6. Check:

drive sprocket

rear wheel sprocket
More than 1 / 4 tooth
a wear
Replace the
drive chain sprockets as a set.
Bent teeth
Replace the drive chain sprock-
ets as a set.
bCorrect
1Drive chain roller
2Drive chain sprocket
EAS00711
INSTALLING THE SWINGARM
1. Lubricate:

bearings

spacers

dust covers

pivot shaft
Recommended lubricant
Lithium-soap-based grease
2. Install:

swingarm

pivot shaft
1

pivot shaft nut 2
3. Install:

rear shock absorber assembly

rear wheel
Refer to “INSTALLING THE REAR SHOCK
ABSORBER ASSEMBLY” and “INSTAL-
LING THE REAR WHEEL”.
4. Adjust:

drive chain slack
Refer to “ADJUSTING THE DRIVE CHAIN
SLACK” in chapter 3.
Drive chain slack
25
35 mm (0.98
1.38 in)
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5-101
Order Job / Part Q’ty Remarks
Disassembling the drive axle
assembly
Washer
1st wheel gear
Collar
5th wheel gear
Circlip
Washer
3rd wheel gear
Collar
Toothed lock washer
Toothed lock washer retainer
4th wheel gear
Collar
Washer
Circlip1
1
1
1
1
1
1
1
1
1
1
1
1
1Disassemble the parts in the order listed.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
TRANSMISSIONENG
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5-102
TRANSMISSIONENG
Order Job / Part Q’ty Remarks
6th wheel gear
Circlip
Washer
Collar
2nd wheel gear
Collar
Oil seal
Bearing
Drive axle1
1
1
1
1
1
1
1
1
For installation, reverse the removal
procedure.
15
16
17
18
19
20
21
22
23
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5-106
TRANSMISSIONENG
10 Nm (1.0 m
kg, 7.2 ft
lb)
NOTE:
NOTE: 3. Install:

shift fork “L”
1 and “R” 2

drive axle assembly 3

shift fork guide bar

shift fork guide bar retainer
4
LOCTITE

Install shift fork “L” into the groove in the 6th
wheel gear and shift fork “R” into the groove in
the 5th wheel gear on the drive axle.

Make sure that the drive axle bearing circlip
a
is inserted into the grooves in the upper crank-
case.
4. Check:

transmission
Rough movement
Repair.
Oil each gear, shaft, and bearing thoroughly.
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8-42
SIGNALING SYSTEMELEC
YESNO 2. Voltage

Connect the pocket tester (DC 20 V) to the
meter assembly coupler (wire harness side)
as shown.
The wiring circuit
from the main switch
to the meter assem-
bly coupler is faulty
and must be re-
paired. Positive tester probe
green / white
Negative tester probe
black / white
1
2

Turn the main switch to “ON”.

Measure the voltage (DC 12 V) of
green / white and black / white at the
meter assembly coupler.

Is the voltage within specification?
This circuit is OK.
12
Replace the multi-
function meter.
NO
1. Multi-function meter bulb socket

Check the multi-function meter bulb socket
for continuity.
Refer to “CHECKING THE BULBS AND
BULB SOCKETS”.

Is the multi-function meter bulb socket OK?
YES
EAS008067. The speedometer fails to come on.
2. Speed sensor

Connect the pocket tester (DC 20 V) to the
speed sensor coupler (wire harness side)
as shown.
Replace the speed
sensor.
NOYES
Positive tester probe
white / yellow
Negative tester probe
black / blue1
2

Set the main switch to “ON”.

Elevate the rear wheel and slowly rotate it.

Measure the voltage (DC 5 V) of white / yel-
low and blue. With each full rotation of the
rear wheel, the voltage reading should cycle
from 0.6 V to 4.8 V to 0.6 V to 4.8 V.

Does the voltage reading cycle correctly?
This circuit is OK.
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