2004 YAMAHA YZF-R1SC engine

5-43
Order Job / Part Q’ty Remarks
1
2
3
4
5
6Removing the crankshaft position
sensor
Rider seat
Fuel tank
Side cowlings
Bottom cowlings
Engine oil
Crankshaft position sensor lead coupler
Crankshaft position sensor
O-ring
Pickup rotor cover
Gasket
Cover1
1
1
1
1
1Remove the parts in the order listed.
Refer to “SEATS” in chapter 3.
Refer to “FUEL TANK” in chapter 3.
Refer to “COWLINGS” in chapter 3.
Drain.
Refer to “CHANGING THE ENGINE OIL”
in chapter 3.
Disconnect.
For installation, reverse the removal
procedure.
10 Nm (1.0 m
kg, 7.2 ft
lb)
12 Nm (1.2 m
kg, 8.7 ft
lb)
12 Nm (1.2 m
kg, 8.7 ft
lb)
12 Nm (1.2 m
kg, 8.7 ft
lb)
CRANKSHAFT POSITION SENSORENG
CRANKSHAFT POSITION SENSOR
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5-44
CRANKSHAFT POSITION SENSORENG
NOTE:
12 Nm (1.2 m
kg, 8.7 ft
lb)
10 Nm (1.0 m
kg, 7.2 ft
lb)
REMOVING THE CRANKSHAFT POSITION
SENSOR
1. Remove:

rider seat

fuel tank
Refer to “SEATS” and “FUEL TANK” in chap-
ter 3.
2. Remove:

right side cowling

bottom cowlings
Refer to “COWLINGS” in chapter 3.
3. Drain:

engine oil
Refer to “CHANGING THE ENGINE OIL” in
chapter 3.
4. Disconnect:

crankshaft position sensor lead coupler
5. Remove:

crankshaft position sensor

O-ring

pickup rotor cover
1
Loosen each bolt 1 / 4 of a turn a time, in stages
and in a crisscross pattern.
After all of the bolts are fully loosened, remove
them.
INSTALLING THE CRANKSHAFT POSITION
SENSOR
1. Install:

gasket
New

pickup rotor cover
1

O-ring New

crankshaft position sensor
LOCTITE
2. Connect:

crankshaft position sensor lead coupler
3. Fill:

engine oil
Refer to “CHANGING THE ENGINE OIL” in
chapter 3.
4. Install:

right side cowling

bottom cowlings
Refer to “COWLINGS” in chapter 3.
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5-46
Order Job / Part Q’ty Remarks
1
2
3
4
5
6Removing the clutch cover
Right side cowling
Bottom cowling
Engine oil
Cover
Clutch cable
Clutch cover
Clutch cover gasket
Dowel pin
Oil filler cap1
1
1
1
2
1Remove the parts in the order listed.
Drain.
Refer to “CHANGING THE ENGINE OIL”
in chapter 3.
Disconnect.
For installation, reverse the removal
procedure.
Refer to “COWLINGS” in chapter 3.
12 Nm (1.2 m
kg, 8.7 ft
lb)
12 Nm (1.2 m
kg, 8.7 ft
lb)
10 Nm (1.0 m
kg, 7.2 ft
lb)
CLUTCHENG
CLUTCH
CLUTCH COVER
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5-54
CLUTCHENG
NOTE:
EAS00286
CHECKING THE PRESSURE PLATE
1. Check:

pressure plate
1
Cracks / damage
Replace.

bearing
2
Damage / wear
Replace.
EAS00287
CHECKING THE PULL LEVER SHAFT AND
PULL ROD
1. Check:

pull lever shaft pinion gear teeth
1

pull rod teeth 2
Damage / wear
Replace the pull rod and
pull lever shaft pinion gear as a set.
2. Check:

pull rod bearing
Damage / wear
Replace.
INSTALLING THE CLUTCH
1. Install:

clutch damper spring seat
1

clutch damper spring 2
2. Install:

friction plate 3
1

clutch plate 2 2
Lubricate the engine oil.
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5-56
CLUTCHENG
NOTE:
10 Nm (1.0 m
kg, 7.2 ft
lb)
NOTE:
NOTE: 6. Lubricate:

friction plates

clutch plates
(with the recommended lubricant)
Recommended lubricant
Engine oil
7. Install:

friction plate 2

clutch plate 1
1
8. Install:

friction plate 1
1
Install the last friction plate shifting half phase.
9. Install:

bearing

pull rod
1

pressure plate 2

clutch springs

clutch spring bolts
3
Tighten the clutch spring bolts in stages and in a
crisscross pattern.
10. Install:

pull lever
In stall the pull lever with the “” mark facing to-
ward upper side.
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5-58
Order Job / Part Q’ty Remarks
1
2
3
4
5
6
7
8
9Removing the shift shaft and stopper
lever
Side cowlings
Bottom cowlings
Clutch assembly
Sift arm and shift rod
Circlip
Washer
Shift shaft
Collar
Shift shaft spring
Washer
Stopper screw
Stopper lever
Washer1
1
1
1
1
1
1
1
1Remove the parts in the order listed.
Refer to “CLUTCH”.
Refer to “ENGINE”.
Refer to “COWLINGS” in chapter 3.
22 Nm (2.2 m
kg, 16 ft
lb)
SHIFT SHAFTENG
EAS00327
SHIFT SHAFT
SHIFT SHAFT AND STOPPER LEVER
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5-60
SHIFT SHAFTENG
REMOVING THE SHIFT SHAFT
1. Remove:

left and right side cowlings

bottom cowlings
Refer to “COWLINGS” in chapter 3.
2. Remove:

clutch assembly
Refer to “CLUTCH”.
3. Remove:

shift arm

shift rod
Refer to “ENGINE”.
4. Remove:

circlip
1

Washer 2
(left side of the engine)
5. Remove:

shift shaft
1

shift shaft spring 2

collar

washer
6. Remove:

stopper lever spring
1

stopper screw 2

stopper lever 3

washer
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5-62
SHIFT SHAFTENG
4. Install:

shift rod

shift arm
Refer to “ENGINE”.
5. Install:

clutch assembly
Refer to “CLUTCH”.
6. Install:

left and side cowling

bottom cowlings
Refer to “COWLING” in chapter 3.
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