YamahaYZFR1SSC2004ServiceManual

EAS00010YZF-R1S/YZF-R1SCSERVICEMANUAL2003byYamahaMotorCorporation,U.S.A.Firstedition,December2003Allrightsreserved.AnyreproductionorunauthorizedusewithoutthewrittenpermissionofYamahaMotorCorporation,U.S.A.isexpresslyprohibited.PrintedinU.S.A.P/NLIT-11616-17-55NOTE:WARNINGCAUTION:EAS00030NOTICEThismanualwasproducedbytheYamahaMotorCompany,Ltd.primarilyforusebyYamahadealersandtheirqualifiedmechanics.Itisnotpossibletoincludealltheknowledgeofamechanicinonemanu-al.Therefore,anyonewhousesthisbooktoperformmaintenanceandrepairsonYamahavehiclesshouldhaveabasicunderstandingofmechanicsandthetechniquestorepairthesetypesofvehicles.Repairandmaintenanceworkattemptedbyanyonewithoutthisknowledgeislikelytorendertheve-hicleunsafeandunfitforuse.Thismodelhasbeendesignedandmanufacturedtoperformwithincertainspecificationsinregardtoperformanceandemissions.Properservicewiththecorrecttoolsisnecessarytoensurethattheve-hiclewilloperateasdesigned.Ifthereisanyquestionaboutaserviceprocedure,itisimperativethatyoucontactaYamahadealerforanyserviceinformationchangesthatapplytothismodel.Thispolicyisintendedtoprovidethecustomerwiththemostsatisfactionfromhisvehicleandtoconformtofederalenvironmentalqualityobjectives.YamahaMotorCompany,Ltd.iscontinuallystrivingtoimproveallofitsmodels.Modificationsandsig-nificantchangesinspecificationsorprocedureswillbeforwardedtoallauthorizedYamahadealersandwillappearinfutureeditionsofthismanualwhereapplicable.
ThisServiceManualcontainsinformationregardingperiodicmaintenancetotheemissioncontrolsystem.Pleasereadthismaterialcarefully.
Designsandspecificationsaresubjecttochangewithoutnotice.EAS00040IMPORTANTMANUALINFORMATIONParticularlyimportantinformationisdistinguishedinthismanualbythefollowing.TheSafetyAlertSymbolmeansATTENTION!BECOMEALERT!YOURSAFETYISINVOLVED!FailuretofollowWARNINGinstructionscouldresultinsevereinjuryordeathtothemotorcycleoperator,abystanderorapersoncheckingorrepairingthemo-torcycle.ACAUTIONindicatesspecialprecautionsthatmustbetakentoavoiddamagetothemotorcycle.NOTE:ANOTEprovideskeyinformationtomakeprocedureseasierorclearer.12483567EAS00007HOWTOUSETHISMANUALThismanualisintendedasahandy,easy-to-readreferencebookforthemechanic.Comprehensiveexplanationsofallinstallation,removal,disassembly,assembly,repairandcheckproceduresarelaidoutwiththeindividualstepsinsequentialorder.1Themanualisdividedintochapters.Anabbreviationandsymbolintheupperrightcornerofeachpageindicatethecurrentchapter.Referto“SYMBOLS”.2Eachchapterisdividedintosections.Thecurrentsectiontitleisshownatthetopofeachpage,exceptinChapter3(“PERIODICCHECKSANDADJUSTMENTS”),wherethesub-sectiontitle(s)ap-pears.3Sub-sectiontitlesappearinsmallerprintthanthesectiontitle.4Tohelpidentifypartsandclarifyproceduresteps,thereareexplodeddiagramsatthestartofeachremovalanddisassemblysection.5Numbersaregivenintheorderofthejobsintheexplodeddiagram.Acirclednumberindicatesadisassemblystep.6Symbolsindicatepartstobelubricatedorreplaced.Referto“SYMBOLS”.7Ajobinstructionchartaccompaniestheexplodeddiagram,providingtheorderofjobs,namesofparts,notesinjobs,etc.8Jobsrequiringmoreinformation(suchasspecialtoolsandtechnicaldata)aredescribedsequen-tially.22135792486242523211920181617151413111210GENINFOSPECENGFIELECCOOLCHKADJTRBLSHTGCHASEAS00008SYMBOLSThefollowingsymbolsarenotrelevanttoeveryvehicle.Symbols1to9indicatethesubjectofeachchapter.1Generalinformation2Specifications3Periodicchecksandadjustments4Chassis5Engine6Coolingsystem7Fuelinjectionsystem8Electricalsystem9TroubleshootingSymbols10to17indicatethefollowing.10Serviceablewithenginemounted11Fillingfluid12Lubricant13Specialtool14Tighteningtorque15Wearlimit,clearance16Enginespeed17ElectricaldataSymbols18to23intheexplodeddiagramsindi-catethetypesoflubricantsandlubricationpoints.18Engineoil19Gearoil20Molybdenum-disulfideoil21Wheel-bearinggrease22Lithium-soap-basedgrease23Molybdenum-disulfidegreaseSymbols24to25intheexplodeddiagramsindi-catethefollowing.24Applylockingagent(LOCTITE)25ReplacethepartGENERALINFORMATIONSPECIFICATIONSPERIODICCHECKSANDADJUSTMENTSCHASSISENGINECOOLINGSYSTEMFUELINJECTIONSYSTEMELECTRICALSYSTEMTROUBLESHOOTINGGENINFO1SPEC23ENG4COOL5FI6CHAS7ELEC8TRBLSHTG9CHKADJEAS00012TABLEOFCONTENTSCHAPTER1GENERALINFORMATIONMOTORCYCLEIDENTIFICATION1-1..............................VEHICLEIDENTIFICATIONNUMBER1-1........................MODELLABEL1-1............................................FEATURES1-2..................................................INSTRUMENTFUNCTIONS1-2.................................IMPORTANTINFORMATION1-6...................................PREPARATIONFORREMOVALANDDISASSEMBLY1-6.........REPLACEMENTPARTS1-6....................................GASKETS,OILSEALSANDO-RINGS1-6.......................LOCKWASHERS/PLATESANDCOTTERPINS1-7..............BEARINGSANDOILSEALS1-7................................CIRCLIPS1-7.................................................CHECKINGTHECONNECTIONS1-8...............................SPECIALTOOLS1-9.............................................CHAPTER2SPECIFICATIONSGENERALSPECIFICAT