air filter YAMAHA YZF-R1SC 2004 Service Manual

LUBRICATION DIAGRAMS2-30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CABLE ROUTING2-35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHAPTER 3
PERIODIC CHECKS AND ADJUSTMENTS
INTRODUCTION3-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PERIODIC MAINTENANCE CHART FOR THE EMISSION
CONTROL SYSTEM3-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL MAINTENANCE AND LUBRICATION CHART3-1 . . . . . . . . .
SEATS3-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FUEL TANK3-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE FUEL TANK 3-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE FUEL PUMP 3-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE FUEL PUMP 3-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE FUEL TANK 3-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
COWLINGS3-7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FRONT COWLING AND SIDE COWLINGS 3-7. . . . . . . . . . . . . . . . . . .
REAR COWLING 3-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVAL 3-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLATION 3-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AIR FILTER CASE3-10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE3-11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ADJUSTING THE VALVE CLEARANCE 3-11. . . . . . . . . . . . . . . . . . . . . .
SYNCHRONIZING THE THROTTLE BODIES 3-17. . . . . . . . . . . . . . . . .
ADJUSTING THE EXHAUST GAS VOLUME 3-19. . . . . . . . . . . . . . . . . .
ADJUSTING THE ENGINE IDLING SPEED 3-21. . . . . . . . . . . . . . . . . . .
ADJUSTING THE THROTTLE CABLE FREE PLAY 3-22. . . . . . . . . . . .
CHECKING THE SPARK PLUGS 3-23. . . . . . . . . . . . . . . . . . . . . . . . . . . .
MEASURING THE COMPRESSION PRESSURE 3-24. . . . . . . . . . . . . .
CHECKING THE ENGINE OIL LEVEL 3-26. . . . . . . . . . . . . . . . . . . . . . . .
CHANGING THE ENGINE OIL 3-28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MEASURING THE ENGINE OIL PRESSURE 3-29. . . . . . . . . . . . . . . . .
ADJUSTING THE CLUTCH CABLE FREE PLAY 3-31. . . . . . . . . . . . . . .
REPLACING THE AIR FILTER ELEMENT 3-32. . . . . . . . . . . . . . . . . . . .
CHECKING THE FUEL AND BREATHER HOSES 3-33. . . . . . . . . . . . .
CHECKING THE CRANKCASE BREATHER HOSE 3-34. . . . . . . . . . . .
CHECKING THE EXHAUST SYSTEM 3-35. . . . . . . . . . . . . . . . . . . . . . . .
ADJUSTING THE EXUP CABLES 3-36. . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE COOLANT LEVEL 3-37. . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE COOLING SYSTEM 3-38. . . . . . . . . . . . . . . . . . . . . . . .
CHANGING THE COOLANT 3-39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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1-3
FEATURES
GEN
INFO
1 Coolant temperature display / air intake
temperature display
2 Odometer / tripmeters / fuel reserve tripme-
ter / stopwatch
3 Shift timing indicator light
NOTE:
NOTE:Odometer, tripmeter, and stopwatch modes
Push the “SELECT” button to switch the display
between the odometer mode “ODO”, the trip-
meter modes “TRIP A” and “TRIP B” and the
stopwatch mode in the following order:
TRIP A
TRIP B
ODO
Stopwatch

TRIP A
If the fuel level warning light comes on, the
odometer display will automatically change to
the fuel reserve tripmeter mode ”F-TRIP” and
start counting the distance traveled from that
point. In that case, push the ”SELECT” button to
switch the display between the various tripme-
ter, odometer, and stopwatch modes in the fol-
lowing order:
F-TRIP
Stopwatch
TRIP A
TRIP B

ODO
F-TRIP
To reset a tripmeter, select it by pushing the “SE-
LECT” button, and then push the “RESET” button
for at least one second. If you do not reset the fuel
reserve tripmeter manually, it will reset itself auto-
matically and the display will return to the prior
mode after refueling and traveling 5 km (3 mi).
Stopwatch mode
Standard measurement
1. Push the “RESET” button to start the stopwatch.
2. Push the “SELECT” button to stop the stopwatch.
3. Push the “SELECT” button again to reset the stopwatch.
Split-time measurement
1. Push the “RESET” button to start the stopwatch.
2. Push the “RESET” button to measure split-times. (The colon “:” will start flashing.)
3. Push the “RESET” button to display the final split-time or push the “SELECT” button to stop the stop-
watch and display total elapsed time.
4. Push the “SELECT” button to reset the stopwatch.
Coolant temperature display
The coolant temperature display indicates the temperature of the coolant. Push the “RESET” button to
switch the coolant temperature display to the air intake temperature display.
When the coolant temperature display is selected, “C” is displayed before the coolant temperature.
Air intake temperature display
The air intake temperature display indicates the temperature of the air drawn into the air filter case. Push
the “RESET” button to switch the coolant temperature display to the air intake temperature display.

Even if the air intake temperature is set to be displayed, the coolant temperature warning light comes
on when the engine overheats.

When the key is turned to “ON”, the coolant temperature is automatically displayed, even if the air
intake temperature was displayed prior to turning the key to “OFF”.

When the air intake temperature display is selected, “A” is displayed before thetemperature.
ProCarManuals.com

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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2-19
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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2-40
P To the air filter
Q Route the fuel tank drain hose
over the canister stay and be-
tween the breather hose 2 and
wire harness. On the front side of
the canister stay, let though the
bottom of the A.C.magneto lead
and the wire harness.
R Route by the upside of vehicle
away from the canister stay.
CABLE ROUTINGSPEC
I The coupler for the air induction
solenoid lead and camshaft sen-
sor lead should be connected
above the ignition coil sub wire
harness and it should not drop
on the cylinder head cover be-
hind the ignition coil.
J Pass the right handlebar switch
lead between the frame and heat
protector.
K Coolant reservoir tank drain
hose should cross with the
speed sensor lead under the
swingarm bracket. Route the
coolant reservoir tank drain hose
over the up side of the vehicle.L Pass the rear brake light switch
lead between the swingarm
bracket and coolant reservoir
tank.
M Release the tip of the clamp and
install it to the clutch cable.
Insert the clamp to the hole lo-
cated on the right back side of
the radiator.
Radiator fan motor lead should
not be caught while inserting the
clamp.
N Push the clamp until it hits the ra-
diator side stay. Radiator fan mo-
tor lead should not be caught.
O Clamp the clutch cable so that it
is within this specified clamp.
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2-46
DD Fasten the wire harness,
A.C.magneto lead, and
throttle body lead with a
clamp. 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 ve-
hicle.
EE To the air filter
FF To the throttle body
GG To install the cover 7, install so
as to set each coupler in the
cover. Make sure that each
lead is not caught by the cover
7.Z Point the tip of the clamp (exces-
sive part) to the down side of the
vehicle. Fasten the wire har-
ness, battery negative lead, A.C.
magneto lead and starter motor
lead with a clamp.
AA To the speed sensor
BB Insert the wire harness wrap-
ping clamp to the hole of the
frame.
CC After passing the lead be-
tween the wire harness and
starter motor leads, fastening
by the clamp should be can-
celled and route the lead un-
der the idle remote controller.
CABLE ROUTINGSPEC
HH Insert the wire harness wrap-
ping clamp to the hole of the
frame.
II Make sure that the lead is fas-
tened with the guide of the ra-
diator stay.
JJ To the right handlebar switch
KK Do not place it beyond pipe 3
in the direction to the external
part of the vehicle.
LL Battery negative lead should
not run on the swingarm
bracket.
ProCarManuals.com

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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3-2
NOTE:
GENERAL MAINTENANCE AND LUBRICATION CHART
CHK
ADJ
NOTE:
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
9*Swingarm pivot
bearings
(See page 4-71)
Check bearing assemblies for looseness.
Moderately repack with lithium-soap-based
grease.
Repack.
10Drive chain
(See page 3-49, 50)
Check chain slack/alignment and condition.
Adjust and lubricate chain with a special O-
ring chain lubricant thoroughly.Every 600 mi (800 km) and after washing the motorcycle or riding in the rain
11*Steering bearings
(See page 3-51)
Check bearing assembly for looseness.
Moderately repack with lithium-soap-based
grease every 16000 mi (25000 km) or 24
months.



Repack.

12*Steering damper
(See page 4-60)
Check operation and for oil leakage.





13*Chassis fasteners
(See page 2-23)
Check all chassis fitting and fasteners.
Correct if necessary.





14Brake and clutch
lever pivot shafts
(See page 3-61)
Apply lithium-soap-based grease (all-purpose
grease) lightly.





15Sidestand pivot(See page 3-61)

Check operation.

Apply lithium-soap-based grease (all-pur-
pose grease) lightly.





16*Sidestand switch
(See page 3-61, 8-4)
Check operation and replace if necessary.






17*Front fork
(See page 3-53)
Check operation and for oil leakage.
Replace if necessary.





18*Shock absorber
assembly
(See page 3-56, 4-67)
Check operation and for oil leakage.
Replace if necessary.





19*Rear suspension
link pivots
(See page 4-71)
Check operation.
Correct if necessary.


20Engine oil
(See page 3-26, 28)
Change (warm engine before draining.)






21*Engine oil filter cartridge
(See page 3-28)
Replace.



22*Cooling system

Check hoses for cracks or damage.
Replace if necessary.





22*Cooling system(See page 3-37, 38, 39)
Change with ethylene glycol antifreeze cool-
ant every 24 months.Change.
23*EXUP system
(See page 3-36)
Check operation, cable free play and pulley
position.
Every 12000 mi (19000 km)
24*Control cables
(See page 3-61)
Apply Yamaha chain and cable lube or en-
gine oil SAE 10W-30 thoroughly.






25*Throttle grip housing
and cable
(See page 3-22)
Check operation and free play.
Adjust the throttle cable free play if necessary.
Lubricate the throttle grip housing and cable.





* Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service.
From 24000 mi (37000 km) or 36 months, repeat the maintenance intervals starting from 8000 mi
(13000 km) or 12 months.
Air filter

This model’s air filter is equipped with a disposable oil-coated paper element, which must not be
cleaned with compressed air to avoid damaging it.

The air filter element needs to be replaced more frequently when riding in unusually wet or dusty areas.
Hydraulic brake service

After disassembling the brake master cylinders and calipers, always change the fluid. Regularly
check the brake fluid levels and fill the reservoirs as required.

Every two years replace the internal components of the brake master cylinders and calipers, and
change the brake fluid.

Replace the brake hoses every four years and if cracked or damaged.
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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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