tow YAMAHA YZF-R1SC 2004 Service Manual

3-39
CHANGING THE COOLANT
CHK
ADJ
CAUTION:
EAS00105
CHANGING THE COOLANT
1. Remove:

bottom cowlings

side cowlings
Refer to “COWLINGS”.

rider seat
Refer to “SEATS”.
2. Remove:

coolant reservoir tank

coolant reservoir hose
3. Disconnect:

coolant reservoir cap
1
4. Drain:

coolant
(from the coolant reservoir tank)
5. Remove:

radiator cap
1
A hot radiator is under pressure. Therefore,
do not remove the radiator cap when the en-
gine is hot. Scalding hot fluid and steam may
be blown out, which could cause serious in-
jury. When the engine has cooled, open the
radiator cap as follows:
Place a thick rag or a towel over the radiator
cap and slowly turn the radiator cap coun-
terclockwise toward the detent to allow any
residual pressure to escape. When the his-
sing sound has stopped, press down on the
radiator cap and turn it counterclockwise to
remove.
The following procedure applies to all of the
coolant drain bolts and copper washers.
6. Remove:

coolant drain bolts
1
(along with the copper washers)
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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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5-19
CAMSHAFTENG
NOTE:
NOTE:
NOTE:
EAS00215
INSTALLING THE CAMSHAFTS
1. Align:

“T” mark
a on the pickup rotor
(with the crankcase mating surface
b)
a. Turn the crankshaft clockwise.
b. When piston #1 is at TDC, align the “T” mark
a with the crankcase mating surface b.
2. Install:

intake camshaft sprocket
1

exhaust camshaft sprocket 2
(with the camshaft sprockets temporarily
tightened)
Install the camshaft sprockets as a illustration.
3. Install:

exhaust camshaft
1

intake camshaft 2
(with the camshaft sprockets temporarily
tightened)
Make sure the punch mark
a faces up.
4. Install:

dowel pins

exhaust camshaft caps

intake camshaft caps

Make sure each camshaft cap is installed in its
original place.

Make sure the arrow mark
a on each cam-
shaft cap points towards the right side of the
engine.
L: Left side camshaft cap mark
R: Right side camshaft cap mark
I: Intake side camshaft cap mark
E: Exhaust side camshaft cap mark
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5-83
CAUTION:
CONNECTING RODS AND PISTONSENG
NOTE:
NOTE:
Do not interchange the big end bearings and
connecting rods. To obtain the correct
crankshaft-pin-to-big-end-bearing clear-
ance and prevent engine damage, the big
end bearings must be installed in their origi-
nal positions.
a. Clean the big end bearings, crankshaft pins,
and the inside of the connecting rods halves.
b. Install the big end upper bearing into the con-
necting rod and the big end lower bearing
into the connecting rod cap.
Align the projections
a on the big end bearings
with the notches
b in the connecting rod and
connecting rod cap.
c. Put a piece of Plastigauge
 1 on the crank-
shaft pin.
d. Assemble the connecting rod halves.

Do not move the connecting rod or crankshaft
until the clearance measurement has been
completed.

Lubricate the bolt threads with molybdenum
disulfide grease.

Make sure that the “Y” mark
c on the connect-
ing rod faces towards the left side of the crank-
shaft.

Make sure that the characters
d on both the
connecting rod and connecting rod cap are
aligned.
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5-90
CONNECTING RODS AND PISTONSENG
NOTE:
20 Nm (2.0 m
kg, 14 ft
lb) + 150
CAUTION:
11. Install:

cylinder assembly
1

connecting rod caps 2

Make sure that the “Y” marks a on the con-
necting rods face towards the left side of the
crankshaft.

Make sure that the characters on both the con-
necting rod and connecting rod cap are
aligned.
12. Tighten:

connecting rod bolts
Tighten the connecting rod bolts using the
plastic-region tightening angle method.
a. Clean the connecting rod bolts.
b. Tighten the connecting rod bolts.
c. Put a mark
1 on the connecting rod bolts 2
and the connecting rod cap 3.
d. Tighten the bolt further to reach the specified
angle (150).
e. After the installation, check that the section
show
a is flush with each other by touching
the surface.

Side machined face
a
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5-105
TRANSMISSIONENG
NOTE:
12 Nm (1.2 m
kg, 8.7 ft
lb)
10 Nm (1.0 m
kg, 7.2 ft
lb)
NOTE: 2. Measure:

drive axle runout
(with a centering device and dial gauge
1)
Out of specification
Replace the drive
axle.
Drive axle runout limit
0.08 mm (0.0032 in)
3. Check:

transmission gears
Blue discoloration / pitting / wear
Replace
the defective gear(s).

transmission gear dogs
Cracks / damage / rounded edges
Replace
the defective gear(s).
INSTALLING THE TRANSMISSION
1. Install:

bearing
1
Make the seal side of bearing face to the outside
and install it close to the right end face of the
crankcase.

oil pipe
2
2. Install:

main axle assembly
1

bearing housing 2
LOCTITE

shift fork “C”

shift drum assembly

shift fork guide bar

shift fork guide bar retainer
LOCTITE

The embossed marks on the shift forks should
face towards the right side of the engine and
be in the following sequence: “R”, “C”, “L”.

Carefully position the shift forks so that they
are installed correctly into the transmission
gears.

Install shift fork “C” into the groove in the 3rd
and 4th pinion gear on the main axle.
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7-5
FUEL INJECTION SYSTEMFI
SUBSTITUTE CHARACTERISTICS OPERATION CONTROL (FAIL-SAFE ACTION)
If the ECU detects an abnormal signal from a sensor while the vehicle is being driven, the ECU illumi-
nates the engine trouble warning light and provides the engine with alternate operating instructions
that are appropriate for the type of malfunction.
When an abnormal signal is received from a sensor, the ECU processes the specified values that are
programmed for each sensor in order to provide the engine with alternate operating instructions that
enable the engine to continue to operate or stop operating, depending on the conditions.
The ECU takes fail-safe actions in two ways: one in which the sensor output is set to a prescribed value,
and the other in which the ECU directly operates an actuator. Details on the fail-safe actions are given
in the table below.
FAIL-SAFE ACTIONS TABLE
Fault
Code No.ItemSymptomFail-safe actionAble / unable
to startAble / unable
to drive
11
Cylinder identification
sensorNo normal signals are received from
the cylinder identification sensor.Continues to operate the engine based
on the results of the cylinder
identification that existed up to that
point.
UnableAble
12Crankshaft position
sensorNo normal signals are received from
the crankshaft position sensor.
Stops the engine (by stopping the
injection and ignition).UnableUnable
13
14Intake air pressure
sensor (open or short
circuit) (pipe system)Intake air pressure sensor-open or
short circuit detected.
Faulty intake air pressure sensor
system.
Fixes the intake air pressure to
101.3 kpa.
AbleAble
15
16Throttle position sensor
(open or short circuit)
(stuck)Throttle position sensor-open or short
circuit detected.
Fixes the throttle position sensor to
fully open.AbleAble
17EXUP servo motor
potention
(open or short circuit)EXUP servo motor potention-open or
short circuit detected.
Turn the EXUP servo motor toward
the open side for 3 seconds and then
stop it.AbleAble
18
EXUP servo motor (lock)A lock of the EXUP servo motor is
detected.
Perform the preventive control
against motor locking.
Perform the lock release operation
twice every 100 seconds.
AbleAble
19Sidestand switch (open
circuit in wire to ECU)Open circuit in the input line of ECU
No.15 terminal is detected when the
start switch is pressed.-- (No start)UnableUnable
20Intake air pressure
Atmospheric pressureDefective values are detected due to
the internal malfunction
Fixes the intake air pressure and
atmospheric pressure to 101.3 kpa.AbleAble
21Coolant temperature
sensorCoolant temperature sensor-open or
short circuit detected.
Fixes the coolant temperature to
60C.AbleAble
22Intake temperature
sensorIntake temperature sensor-open or
short circuit detected.
Fixes the intake temperature to 20C.AbleAble
23Atmospheric pressure
sensorAtmospheric pressure sensor-open or
short circuit detected.
Fixes the atmospheric pressure to
101.3 kpa.AbleAble
33
34
35
36
Faulty ignitionOpen circuit detected in the primary
lead of the ignition coil.
Cut the injection of other cylinder in
the same group with the cylinder that
the error is detected.
(Example: when the #1 cylinder is
detective, cut the injection of #1 and
#4 cylinders, when the #2 cylinder is
detective, cut the injection of #2 and
#3 cylinders).
Turn on the power to the air induction
solenoid to always cut-off the air.
Able
(depending
on the num-
ber of faulty
cylinders)Able
(depending
on the num-
ber of faulty
cylinders)
30
41Lean angle cut-off
switch (latch up
detected) (open or short
circuit)Lean angle cut-off switch-open or short
circuit detected.
Turns OFF the fuel injection system
relay of the fuel system.
UnableUnable
42Speed sensor, neutral
switchNo normal signals are received from the
speed sensor; or, an open or short
circuit is detected in the neutral switch.
Fixes the gear to the top gear.AbleAble
43Fuel system voltage
(monitor voltage)The ECU is unable to monitor the
battery voltage (an open circuit in the
line to the ECU).
Fixes the battery voltage to 12 V.AbleAble
44
Error in writing the
amount of CO
adjustment on
EEPROMAn error is detected while reading or
writing on EEPROM (CO adjustment
value).--
AbleAble
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7-6
FUEL INJECTION SYSTEMFI
Fault
Code No.ItemSymptomFail-safe actionAble / unable
to startAble / unable
to drive
46Vehicle system power
supply (Monitor voltage)Power supply to the FI system is not
normal.--AbleAble
47Sub-throttle servo motor
potention (open or short
circuit)sub-throttle servo motor potention-
open or short circuit detected.
Turn the sub-throttle servo motor
toward the close side for 4 seconds
and then stop it.AbleAble
48
Sub-throttle servo motor
(lock)A lock of the sub-throttle servo motor is
detected.
Perform the preventative control
against motor locking.
(Perform the lock release operation
twice every 100 seconds.)
AbleAble
50ECU internal
malfunction (memory
check error)Faulty ECU memory. When this
malfunction is detected, the code
number might not appear on the meter.--UnableUnable
—
Start unable warningRelay is not turned ON even if the crank
signal is input while the start switch is
turned ON.
When the start switch is turned ON
while an error is detected with the fault
code of No.11, 12, 19, 30, 41 or 50.Engine trouble warning light flashes
when the start switch is turned ON.
UnableUnable
Communication error with the meter
Fault
Code No.ItemSymptomFail-safe actionAble / unable
to startAble / unable
to drive
Er-1ECU internal malfunction
(output signal error)No signals are received from the ECU.–UnableUnable
Er-2ECU internal malfunction
(output signal error)No signals are received from the ECU
within the specified duration.–UnableUnable
Er-3ECU internal malfunction
(output signal error)Data from the ECU cannot be received
correctly.–UnableUnable
Er-4ECU internal malfunction
(input signal error)Non-registered data has been received
from the meter.–UnableUnable
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