engine YAMAHA YZF-R1SC 2004 Repair Manual

4-74
SWINGARM AND DRIVE CHAINCHAS
CAUTION:
2. Check:

drive chain
Stiffness
Clean and lubricate or replace.
3. Clean:

drive chain
a. Wipe the drive chain with a clean cloth.
b. Put the drive chain in kerosene and remove
any remaining dirt.
c. Remove the drive chain from the kerosene
and completely dry it.
This motorcycle has a drive chain with small
rubber O-rings
1 between the drive chain
side plates. Never use high-pressure water
or air, steam, gasoline, certain solvents
(e.g., benzine), or a coarse brush to clean the
drive chain. High-pressure methods could
force dirt or water into the drive chain’s in-
ternals, and solvents will deteriorate the O-
rings. A coarse brush can also damage the
O-rings. Therefore, use only kerosene to
clean the drive chain. Don’t soak drive chain
in kerosine more them ten minutes. O-ring is
damage by kerosine.
4. Check:

O-rings
1
Damage
Replace the drive chain.

drive chain rollers
2
Damage / wear
Replace the drive chain.

drive chain side plates
3
Damage / wear
Replace the drive chain.
Cracks
Replace the drive chain and make
sure the battery breather hose is properly
routed away from the drive chain and below
the swingarm.
5. Lubricate:

drive chain
Recommended lubricant
Engine oil or chain lubricant
suitable for O-ring chains
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5-1
Order Job / Part Q’ty Remarks
1
2
3
4
5
6
7
8Removing the drive sprocket
Bottom cowlings
Lock nut
Shift rod
Sift arm
Drive sprocket cover
Drive sprocket nut
Lock washer
Drive sprocket
Plate2
1
1
1
1
1
1
1Remove the parts in the order listed.
Refer to “COWLINGS” in chapter 3.
Loosen.
For installation, reverse the removal
procedure.
10 Nm (1.0 m
kg, 7.2 ft
lb)
85 Nm (8.5 m
kg, 61 ft
lb)
7 Nm (0.7 m
kg, 5 ft
lb)
10 Nm (1.0 m
kg, 7.2 ft
lb)
ENGINEENG
ENGINE
ENGINE
DRIVE SPROCKET
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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 m
kg, 7.2 ft
lb)
10 Nm (1.0 m
kg, 7.2 ft
lb)
10 Nm (1.0 m
kg, 7.2 ft
lb)
20 Nm (2.0 m
kg, 14 ft
lb)
20 Nm (2.0 m
kg, 14 ft
lb)
20 Nm (2.0 m
kg, 14 ft
lb)
23 Nm (2.3 m
kg, 17 ft
lb)
ENGINEENG
EXHAUST PIPE
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5-3
Order Job / Part Q’ty Remarks
11
12
13
14Muffler cover
EXUP servo motor
EXUP servo motor bracket
Protector2
1
1
1
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)
10 Nm (1.0 m
kg, 7.2 ft
lb)
20 Nm (2.0 m
kg, 14 ft
lb)
20 Nm (2.0 m
kg, 14 ft
lb)
20 Nm (2.0 m
kg, 14 ft
lb)
23 Nm (2.3 m
kg, 17 ft
lb)
ENGINEENG
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5-4
ENGINEENG
Order Job / Part Q’ty Remarks
Disassembling the exhaust valve
pipe
Washer
Pulley
Collar
Plate
Spring
Housing
Gasket
Shaft arm
Exhaust valve pipe
EXUP pulley bracket1
1
1
1
1
1
1
1
1
1Disassemble the parts in the order listed.
For assembly, reverse the disassembly
procedure.
1
2
3
4
5
6
7
8
9
10
10 Nm (1.0 m
kg, 7.2 ft
lb)
10 Nm (1.0 m
kg, 7.2 ft
lb)
7 Nm (0.7 m
kg, 5 ft
lb)
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5-5
Order Job / Part Q’ty Remarks
1
2Disconnecting the leads and hoses
Fuel tank
Air filter case
Throttle body assembly
Engine oil
Oil cooler
Air cut-off valve
Starter motor
Battery negative lead
Battery positive lead1
1Disconnect the parts in the order listed.
Refer to “FUEL TANK” in chapter 3.
Refer to “AIR FILTER CASE” in chapter 3.
Refer to “THROTTLE BODIES” in
chapter 7.
Drain.
Refer to “CHANGING THE ENGINE OIL”
in chapter 3.
Refer to “OIL COOLER” in chapter 6.
Refer to “AIR INDUCTION SYSTEM” in
chapter 7.
Refer to “STARTING SYSTEM” in
chapter 7.
ENGINEENG
LEADS AND HOSES
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5-6
Order Job / Part Q’ty Remarks
3
4
5
6
7
8
9
10Clutch cable
Ground lead
Stator coil assembly coupler
Crankshaft position sensor lead coupler
Oil level switch connector
Neutral switch connector
Speed sensor coupler
Cylinder identification sensor coupler1
2
1
1
1
1
1
1First, disconnect the negative battery
lead, and then the positive battery lead.
For connecting, reverse the disconnec-
tion procedure.
Disconnect.
Disconnect.
Disconnect.
Disconnect.
Disconnect.
Disconnect.
For installation, reverse the removal
procedure.
CAUTION:
ENGINEENG
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5-7
ENGINEENG
Order Job / Part Q’ty Remarks
1
2
3
4
5
6
7
8Removing the engine
Right front engine mounting bolt
Engine mount collar (inside)
Engine mount collar (outside)
Left front engine mounting bolt
Lower self locking nut
Lower engine mounting bolt
Upper self locking nut
Upper engine mounting bolt1
1
1
1
1
1
1
1Remove the parts in the order listed.
Place a suitable stand under the frame and
engine.
NOTE:
51 Nm (5.1 m
kg, 37 ft
lb)
51 Nm (5.1 m
kg, 37 ft
lb)
45 Nm (4.5 m
kg, 33 ft
lb)
7 Nm (0.7 m
kg, 5.1 ft
lb)
45 Nm (4.5 m
kg, 33 ft
lb)
ENGINE
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5-8
ENGINEENG
Order Job / Part Q’ty Remarks
9
10Engine mounting adjust bolt
Engine2
1 Use the pivot shaft wrench and adapter to
loosen the engine mounting adjust bolts.
For installation, reverse the removal pro-
cedure.
NOTE:
51 Nm (5.1 m
kg, 37 ft
lb)
51 Nm (5.1 m
kg, 37 ft
lb)
45 Nm (4.5 m
kg, 33 ft
lb)
7 Nm (0.7 m
kg, 5.1 ft
lb)
45 Nm (4.5 m
kg, 33 ft
lb)
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5-9
ENGINEENG
NOTE:
7 Nm (0.7 m
kg, 5.1 ft
lb)
NOTE: INSTALLING THE ENGINE
1. Install:

engine mounting adjust bolts
(temporary tighten)
2. Install:

engine
3. Install:

lower engine mounting bolt
1

upper engine mounting bolt 2

self locking nuts
Lubricate the lower and upper engine mounting
bolts threads with lithium-soap-based grease.
4. Install:

left front engine mount bolt
1
(temporary tighten)
5. Install:

engine mount collar (inside)
1

engine mount collar (outside) 2

right front engine mount bolt 3
(temporary tighten)
6. Tighten:

engine mounting adjust bolts
Use the pivot shaft wrench
1 and pivot shaft
wrench adapter
2 to tighten the engine mount-
ing adjust bolts.
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