brake fluid YAMAHA YZF-R1SC 2004 Service Manual

CHASSIS3-42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ADJUSTING THE FRONT BRAKE 3-42. . . . . . . . . . . . . . . . . . . . . . . . . . .
ADJUSTING THE REAR BRAKE 3-43. . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE BRAKE FLUID LEVEL 3-44. . . . . . . . . . . . . . . . . . . . . .
ADJUSTING THE REAR BRAKE LIGHT SWITCH 3-45. . . . . . . . . . . . .
CHECKING THE FRONT AND REAR BRAKE PADS 3-45. . . . . . . . . . .
CHECKING THE FRONT AND REAR BRAKE HOSES 3-46. . . . . . . . .
BLEEDING THE HYDRAULIC BRAKE SYSTEM 3-47. . . . . . . . . . . . . . .
ADJUSTING THE SHIFT PEDAL 3-48. . . . . . . . . . . . . . . . . . . . . . . . . . . .
ADJUSTING THE DRIVE CHAIN SLACK 3-49. . . . . . . . . . . . . . . . . . . . .
LUBRICATING THE DRIVE CHAIN 3-50. . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING AND ADJUSTING THE STEERING HEAD 3-51. . . . . . . . .
CHECKING THE FRONT FORK 3-53. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ADJUSTING THE FRONT FORK LEGS 3-54. . . . . . . . . . . . . . . . . . . . . .
ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY 3-56. . . . .
CHECKING THE TIRES 3-58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE WHEELS 3-60. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING AND LUBRICATING THE CABLES 3-61. . . . . . . . . . . . . . .
LUBRICATING THE LEVERS AND PEDALS 3-61. . . . . . . . . . . . . . . . . .
LUBRICATING THE SIDESTAND 3-61. . . . . . . . . . . . . . . . . . . . . . . . . . . .
LUBRICATING THE REAR SUSPENSION 3-61. . . . . . . . . . . . . . . . . . . .
ELECTRICAL SYSTEM3-62 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING AND CHARGING THE BATTERY 3-62. . . . . . . . . . . . . . . . .
CHECKING THE FUSES 3-67. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REPLACING THE HEADLIGHT BULBS 3-69. . . . . . . . . . . . . . . . . . . . . .
ADJUSTING THE HEADLIGHT BEAMS 3-70. . . . . . . . . . . . . . . . . . . . . .
CHAPTER 4
CHASSIS
FRONT WHEEL AND BRAKE DISCS4-1 . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE FRONT WHEEL 4-3. . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE FRONT WHEEL 4-3. . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE BRAKE DISCS 4-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE FRONT WHEEL 4-6. . . . . . . . . . . . . . . . . . . . . . . . . . .
ADJUSTING THE FRONT WHEEL STATIC BALANCE 4-7. . . . . . . . .
REAR WHEEL AND BRAKE DISC4-9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REAR WHEEL 4-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REAR BRAKE DISC AND REAR WHEEL SPROCKET 4-10. . . . . . . . .
REMOVING THE REAR WHEEL 4-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE REAR WHEEL 4-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE REAR WHEEL DRIVE HUB 4-13. . . . . . . . . . . . . . . . .
CHECKING AND REPLACING THE REAR WHEEL
SPROCKET 4-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE REAR WHEEL 4-14. . . . . . . . . . . . . . . . . . . . . . . . . . . .
ADJUSTING THE REAR WHEEL STATIC BALANCE 4-14. . . . . . . . . . .
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2-12
CHASSIS SPECIFICATIONSSPEC
ItemStandardLimit
Front brakes
Brake type
Operation
Recommended fluid
Brake lever free play
Brake discs
Diameter
thickness
Min. thickness
Max. deflection
Brake pad lining thickness (inner)
Brake pad lining thickness (outer)
Master cylinder inside diameter
Caliper cylinder inside diameter
Dual disc brake
Right hand operation
DOT 4
2.3  11.5 mm (0.09  0.45 in)
320
4.5 mm (12.60
0.18 in)








4.5 mm (0.18 in)
4.5 mm (0.18 in)
14 mm (0.55 in)
30.1 mm and 27 mm (1.19 in and 1.06 in)



















4.0 mm
(0.16 in)
0.1 mm
(0.004 in)
0.5 mm
(0.02 in)
0.5 mm
(0.02 in)








Rear brake
Brake type
Operation
Recommended fluid
Brake pedal freeplay
Brake discs
Diameter
thickness
Min. thickness
Max. deflection
Brake pad lining thickness (inner)
Brake pad lining thickness (outer)
Master cylinder inside diameter
Caliper cylinder inside diameter
Single disc brake
Right foot operation
DOT 4
4.3  9.3 mm (0.17  0.37 in)
220
5 mm (8.66
0.20 in)








6.0 mm (0.24 in)
6.0 mm (0.24 in)
12.7 mm (0.5 in)
31.8 mm (1.25 in)



















4.5 mm
(0.18 in)
0.15 mm
(0.006 in)
1.0 mm
(0.04 in)
1.0 mm
(0.04 in)








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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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3-44
A
B
CHECKING THE BRAKE FLUID LEVEL
CHK
ADJ
NOTE:
WARNING
CAUTION:
NOTE:
EAS00115
CHECKING THE BRAKE FLUID LEVEL
1. Stand the motorcycle on a level surface.

Place the motorcycle on a suitable stand.

Make sure the motorcycle is upright.
2. Check:

brake fluid level
Below the minimum level mark
a
Add the
recommended brake fluid to the proper level.
Recommended brake fluid
DOT 4
AFront brake
BRear brake

Use only the designated brake fluid. Other
brake fluids may cause the rubber seals to
deteriorate, causing leakage and poor
brake performance.

Refill with the same type of brake fluid that
is already in the system. Mixing brake
fluids may result in a harmful chemical
reaction, leading to poor brake perfor-
mance.

When refilling, be careful that water does
not enter the brake fluid reservoir. Water
will significantly lower the boiling point of
the brake fluid and could cause vapor lock.
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean
up any spilt brake fluid immediately.
In order to ensure a correct reading of the brake
fluid level, make sure the top of the brake fluid
reservoir is horizontal.
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3-46
B
A
B
A
CHECKING THE FRONT AND REAR BRAKE PADS
/
CHECKING THE FRONT AND REAR BRAKE HOSESCHK
ADJ
2. Check:

front brake pad

rear brake pad
Brake pad wear limit
a, b
Wear limit reached
Replace the brake
pads as a set.
Refer to “FRONT AND REAR BRAKES” in
chapter 7.
Brake pad wear limit
a 0.5 mm (0.02 in)
b 1.0 mm (0.04 in)
AFront brake
BRear brake
EAS00131
CHECKING THE FRONT AND REAR BRAKE
HOSES
The following procedure applies to all of the
brake hoses and brake hose clamps.
1. Check:

brake hose
1
Cracks / damage / wear
Replace.
AFront
BRear
2. Check:

brake hose clamp
2
Loose
Tighten the clamp bolt.
3. Hold the motorcycle upright and apply the
brake several times.
4. Check:

brake hose
Brake fluid leakage
Replace the damaged
hose.
Refer to “FRONT AND REAR BRAKES” in
chapter 4.
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3-47
B
C
A
BLEEDING THE HYDRAULIC BRAKE SYSTEM
CHK
ADJ
WARNING
NOTE:
NOTE:
EAS00135
BLEEDING THE HYDRAULIC BRAKE
SYSTEM
Bleed the hydraulic brake system whenev-
er:

the system is disassembled.

a brake hose is loosened, disconnected or
replaced.

the brake fluid level is very low.

brake operation is faulty.

Be careful not to spill any brake fluid or allow
the brake fluid reservoir to overflow.

When bleeding the hydraulic brake system,
make sure there is always enough brake fluid
before applying the brake. Ignoring this pre-
caution could allow air to enter the hydraulic
brake system, considerably lengthening the
bleeding procedure.

If bleeding is difficult, it may be necessary to let
the brake fluid settle for a few hours. Repeat
the bleeding procedure when the tiny bubbles
in the hose have disappeared.
1. Bleed:

hydraulic brake system
a. Fill the brake fluid reservoir to the proper lev-
el with the recommended brake fluid.
b. Install the brake fluid reservoir diaphragm.
c. Connect a clear plastic hose
1 tightly to the
bleed screw
2.
AFront brake master cylinder
BFront brake caliper
CRear brake caliper
Bleeding order of the front hydraulic brake sys-
tem is the following order:
1. front brake master cylinder.
2. front brake calipers.
3. front brake master cylinder.
d. Place the other end of the hose into a con-
tainer.
e. Slowly apply the brake several times.
f. Fully pull the brake lever or fully press down
the brake pedal and hold it in position.
g. Loosen the bleed screw.
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3-48
BLEEDING THE HYDRAULIC BRAKE SYSTEM /
ADJUSTING THE SHIFT PEDALCHK
ADJ
NOTE:
WARNING
NOTE:
a
b
Loosening the bleed screw will release the pres-
sure and cause the brake lever to contact the
throttle grip or the brake pedal to fully extend.
h. Tighten the bleed screw and then release the
brake lever or brake pedal.
i. Repeat steps (e) to (h) until all of the air
bubbles have disappeared from the brake
fluid in the plastic hose.
j. Tighten the bleed screw to specification.
Bleed screw
6 Nm (0.6 m
kg, 4.3 ft
lb)
k. Fill the brake fluid reservoir to the proper lev-
el with the recommended brake fluid.
Refer to “CHECKING THE BRAKE FLUID
LEVEL”.
After bleeding the hydraulic brake system,
check the brake operation.
After bleeding air, the brake fluid may ooze
around the thread section of each bleed screw.
This phenomenon does not show the leakage
but the brake fluid that has been accumulated in
the thread of screw while bleeding air. Please
wipe off to make the parts clean.
EAS00136
ADJUSTING THE SHIFT PEDAL
1. Adjust:

shift pedal position
a. Loosen both locknuts
1.
b. Turn the shift rod
2 in direction a or b to
obtain the correct shift pedal position.
Direction
Shift pedal is raised.
DirectionShift pedal is lowered.
c. Tighten both locknuts.
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4-17
FRONT AND REAR BRAKESCHAS
CAUTION:
WARNING
EAS00579
Disc brake components rarely require dis-
assembly.
Therefore, always follow these preventive
measures:

Never disassemble brake components un-
less absolutely necessary.

If any connection on the hydraulic brake
system is disconnected, the entire brake
system must be disassembled, drained,
cleaned, properly filled, and bled after reas-
sembly.

Never use solvents on internal brake com-
ponents.

Use only clean or new brake fluid for clean-
ing brake components.

Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean
up any spilt brake fluid immediately.

Avoid brake fluid coming into contact with
the eyes as it can cause serious injury.
FIRST AID FOR BRAKE FLUID ENTERING
THE EYES:

Flush with water for 15 minutes and get im-
mediate medical attention.
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4-19
FRONT AND REAR BRAKESCHAS
NOTE:
NOTE:
35 Nm (3.5 m
kg, 25 ft
lb)
5. Install:

brake pad shims
(onto the brake pads)

brake pads

brake pad spring
Always install new brake pads, brake pad
shims, and a brake pad spring as a set.
a. Connect a clear plastic hose
1 tightly to the
bleed screw
2. Put the other end of the hose
into an open container.
b. Loosen the bleed screw and push the brake
caliper pistons into the brake caliper with
your finger.
c. Tighten the bleed screw.
Bleed screw
5 Nm (0.5 m
kg, 3.6 ft
lb)
d. Install a new brake pad shim onto each new
brake pad.
Install the brake pad spring pointing
a toward
the bleed screw.
e. Install new brake pads and a new brake pad
spring.
6. Install:

brake pad pins

brake pad clips

brake caliper
7. Check:

brake fluid level
Below the minimum level mark
a
Add the
recommended brake fluid to the proper level.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” in chapter 3.
8. Check:

brake lever operation
Soft or spongy feeling
Bleed the brake
system.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
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