transmission YAMAHA YZF-R1SC 2004 Service Manual

CRANKCASE5-72 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DISASSEMBLING THE CRANKCASE 5-74. . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE CRANKCASE 5-75. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE BEARINGS AND OIL SEALS 5-75. . . . . . . . . . . . . . . .
ASSEMBLING THE CRANKCASE 5-75. . . . . . . . . . . . . . . . . . . . . . . . . . .
CONNECTING RODS AND PISTONS5-77 . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE CONNECTING RODS AND PISTONS 5-78. . . . . . . .
REMOVING THE CRANKSHAFT ASSEMBLY 5-79. . . . . . . . . . . . . . . . .
CHECKING THE CYLINDER AND PISTON 5-79. . . . . . . . . . . . . . . . . . .
CHECKING THE PISTON RINGS 5-80. . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE PISTON PINS 5-81. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE BIG END BEARINGS 5-82. . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE CONNECTING ROD AND PISTON 5-86. . . . . . . . . .
CRANKSHAFT5-92 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE CRANKSHAFT 5-93. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE CRANKSHAFT DRIVE SPROCKET 5-93. . . . . . . . . .
CHECKING THE CRANKSHAFT JOURNAL BEARINGS 5-93. . . . . . . .
INSTALLING THE CRANKSHAFT 5-96. . . . . . . . . . . . . . . . . . . . . . . . . . . .
TRANSMISSION5-97 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TRANSMISSION, SHIFT DRUM ASSEMBLY AND
SHIFT FORKS 5-97. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE TRANSMISSION 5-103. . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE SHIFT FORKS 5-103. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE SHIFT DRUM ASSEMBLY 5-104. . . . . . . . . . . . . . . . . . .
CHECKING THE TRANSMISSION 5-104. . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE TRANSMISSION 5-105. . . . . . . . . . . . . . . . . . . . . . . . . .
CHAPTER 6
COOLING SYSTEM
RADIATOR6-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE RADIATOR 6-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE RADIATOR 6-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OIL COOLER6-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE OIL COOLER 6-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE OIL COOLER 6-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
THERMOSTAT6-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE THERMOSTAT 6-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ASSEMBLING THE THERMOSTAT ASSEMBLY 6-11. . . . . . . . . . . . . . .
INSTALLING THE THERMOSTAT ASSEMBLY 6-11. . . . . . . . . . . . . . . .
WATER PUMP6-12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
IMPELLER SHAFT 6-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DISASSEMBLING THE WATER PUMP 6-14. . . . . . . . . . . . . . . . . . . . . . .
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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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2-25
LUBRICATION POINTS AND LUBRICANT TYPESSPEC
EAS00031
LUBRICATION POINTS AND LUBRICANT TYPES
ENGINE
Lubrication point
Lubricant
Oil seal lips
O-rings
Bearings
Crankshaft pins
Piston surfaces
Piston pins
Crankshaft journals
Camshaft lobes
Camshaft journals
Valve stems (intake and exhaust)
Valve stem ends (intake and exhaust)
Water pump impeller shaft
Oil pump rotors (inner and outer)
Oil pump housing
Oil strainer
Clutch (pull rod)
Oil / water pump drive sprocket and washer
Clutch (thrust plate)
Starter clutch idle gear inner surface
Starter clutch assembly
Primary driven gear
Transmission gears (wheel and pinion)
Main axle and drive axle
Shift drum
Shift forks and shift fork guide bars
Shift shaft
Shift shaft boss
Cylinder head cover mating surfaceYamaha bond
No.1215
Crankcase mating surfaceYamaha bond
No.1215
Clutch cover (crankcase mating surface)Yamaha bond
No.1215
Generator rotor cover (crankcase mating surface)Yamaha bond
No.1215
Pickup rotor coverYamaha bond
No.1215
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5-76
CRANKCASEENG
CAUTION:
NOTE:
3. Install:

dowel pin
4. Set the shift drum assembly and transmis-
sion gears in the neutral position.
5. Install:

lower crankcase
1
(onto the upper crankcase 2)
Before tightening the crankcase bolts, make
sure that the transmission gears shift cor-
rectly when the shift drum assembly is
turned by hand.
6. Install:

crankcase bolts

Lubricate the bolt threads with engine oil.

Install a washer on bolts
1
10 and 22.

Seal bolt
18

Tighten the bolts in the tightening sequence
cast on the crankcase.
M9  105 mm (4.1 in) bolts:
1
10
M8  60 mm (2.4 in) bolt: 11 LOCTITE
M8  60 mm (2.4 in) bolts: 12, 16
M6  70 mm (2.8 in) bolts: 19, 21, 23
M6  65 mm (2.5 in) bolts: 17, 18
M6  60 mm (2.4 in) bolts: 22, 24, 25
M6  50 mm (2.0 in) bolts: 20, 26
M8  50 mm (2.0 in) bolts: 13
15
Crankcase bolt
Bolt
1
10
1st: 20 Nm (2.0 m
kg, 14 ft
lb)
2nd*: 20 Nm (2.0 m
kg, 14 ft
lb)
3rd: +60
Bolt
11
16
24 Nm (2.4 m
kg, 17 ft
lb)
Bolt
17
26
12 Nm (1.2 m
kg, 8.7 ft
lb)
* Following the tightening order, loosen the bolt
one by one and then retighten it to the specific
torque.
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5-97
Order Job / Part Q’ty Remarks
1
2
3
4
5
6
7
8
9
10
11
12Removing the transmission, shift
drum assembly, and shift forks
Crankcase lower
Drive axle assembly
Circlip
Oil seal
Bearing
Washer
Shift drum retainer
Spring
Shift fork guide bar
Shift fork “L”
Shift fork “R”
Shift drum assembly
Shift fork “C”1
1
1
1
1
2
2
2
1
1
1
1Remove the part in the order listed.
Separate.
Refer to “CRANKCASE”.
12 Nm (1.2 m
kg, 8.7 ft
lb)
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)
TRANSMISSIONENG
EAS00419
TRANSMISSION
TRANSMISSION, SHIFT DRUM ASSEMBLY AND SHIFT FORKS
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5-98
TRANSMISSIONENG
Order Job / Part Q’ty Remarks
13
14
15
16
17Main axle retainer
Main axle assembly
Oil pipe
O-ring
Oil baffle plate1
1
1
2
1
For installation, reverse the removal
procedure.
12 Nm (1.2 m
kg, 8.7 ft
lb)
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)
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5-99
Order Job / Part Q’ty Remarks
Disassembling the main axle
assembly
2nd pinion gear
Toothed lock washer
Toothed lock washer retainer
6th pinion gear
Collar
Washer
Circlip
3rd pinion gear
Circlip
Washer
5th pinion gear
Collar
Main axle1
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
TRANSMISSIONENG
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5-100
Order Job / Part Q’ty Remarks
Bearing housing
Bearing1
1
For installation, reverse the removal
procedure.
14
15
TRANSMISSIONENG
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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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