2004 YAMAHA YZF-R1SC brake light

2-45
W Point the tip of the clamp (sur-
plus section) to the rear side of
the vehicle. Fasten the starter
relay lead, turn signal relay lead,
main fuse lead, main fuse lead
(from the battery positive lead)
and starting circuit cut-off relay
lead with a clamp.
X Route each lead under the wire
harness.
Y Fasten the wire harness, battery
negative lead and starter motor
lead with a clamp. Point the tip of
the clamp (excessive part) to the
inside of the vehicle.P Pass the lead through inside of
the battery band.
Q Press on the tip of the clamp af-
ter passing the leads through it.
R Insert the tail / brake light lead to
the rear frame hole.
S Insert the clamp from the vehicle
front to the rear side and fasten
each lead, coupler and onion-
head to the fender rib, and then
point the tip of the clamp (exces-
sive part) to the upper side of the
vehicle.
T Hold down the clamp tips after
passing each lead.U Make sure to position the cou-
pler at the downmost position of
leads. However, the coupler
should be set in the rear frame so
that it is not caught by the seat
bottom, cover and other compo-
nents.
V Point the tip of the clamp (exces-
sive part) to the inside of the ve-
hicle. Fasten the wire harness
with a clamp.
CABLE ROUTINGSPEC
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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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3-8
Order Job / Part Q’ty Remarks
1
2
3
4
5
6Removing the rear cowling
Rider seat and passenger seat
Muffler
Rear cowling (upper)
Tail / brake light lead coupler
Rear turn signal light lead coupler
Tail / brake light
License plate bracket assembly
Rear cowling (lower)1
1
4
1
1
1Remove the parts in the order listed.
Refer to “SEATS”.
Refer to “EXHAUST PIPE” in chapter 5.
Disconnect.
Disconnect.
For installation, reverse the removal
procedure.
4 Nm (0.4 m
kg, 2.9 ft
lb)10 Nm (1.0 m
kg, 7.2 ft
lb)
COWLINGS
CHK
ADJ
REAR COWLING
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3-43
ADJUSTING THE REAR BRAKE
CHK
ADJ
a
b
WARNING
WARNING
CAUTION:
EAS00110
ADJUSTING THE REAR BRAKE
1. Adjust:

brake pedal position
a. Loosen the locknut
1.
b. Turn the adjusting bolt
2 in direction a or b
until the specified brake pedal position is ob-
tained.
Direction
Brake pedal is raised.
DirectionBrake pedal is lowered.
After adjusting the brake pedal position,
check that the end of the adjusting bolt
c is
visible through the hole
d.
c. Tighten the locknut
1 to specification.
Locknut
16 Nm (1.6 m
kg, 12 ft
lb)
A soft or spongy feeling in the brake pedal
can indicate the presence of air in the brake
system. Before the vehicle is operated, the
air must be removed by bleeding the brake
system. Air in the brake system will consid-
erably reduce braking performance and
could result in loss of control and possibly
an accident. Therefore, check and, if neces-
sary, bleed the brake system.
After adjusting the brake pedal position,
make sure there is no brake drag.
2. Adjust:

rear brake light switch
Refer to “ADJUSTING THE REAR BRAKE
LIGHT SWITCH”.
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3-45
ADJUSTING THE REAR BRAKE LIGHT SWITCH /
CHECKING THE FRONT AND REAR BRAKE PADSCHK
ADJ
NOTE:
a
b
EAS00128
ADJUSTING THE REAR BRAKE LIGHT
SWITCH
The rear brake light switch is operated by move-
ment of the brake pedal.
The rear brake light switch is properly adjusted
when the brake light comes on just before the
braking effect starts.
1. Check:

rear brake light operation timing
Incorrect
Adjust.
2. Adjust:

rear brake light operation timing
a. Hold the main body
1 of the rear brake light
switch so that it does not rotate and turn the
adjusting nut
2 in direction a or b until the
rear brake light comes on at the proper time.
Direction
Brake light comes on
sooner.
DirectionBrake light comes on
later.
EAS00122
CHECKING THE FRONT AND REAR BRAKE
PADS
The following procedure applies to all of the
brake pads.
1. Operate the brake.
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4-8
FRONT WHEEL AND BRAKE DISCSCHAS
NOTE:
3. Adjust:

front wheel static balance
a. Install a balancing weight
1 onto the rim ex-
actly opposite the heavy spot “X”.
Start with the lightest weight.
b. Turn the front wheel 90 so that the heavy
spot is positioned as shown.
c. If the heavy spot does not stay in that posi-
tion, install a heavier weight.
d. Repeat steps (b) and (c) until the front wheel
is balanced.
4. Check:

front wheel static balance
a. Turn the front wheel and make sure it stays at
each position shown.
b. If the front wheel does not remain stationary
at all of the positions, rebalance it.
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4-23
FRONT AND REAR BRAKESCHAS
Order Job / Part Q’ty Remarks
10
11
12
13
14Copper washer
Brake hose
Brake master cylinder bracket
Brake master cylinder
Front brake light switch2
1
1
1
1
For installation, reverse the removal
procedure.
3.8 Nm (0.38 m
kg, 2.7 ft
lb)
1.2 Nm (0.12 m
kg, 0.9 ft
lb)
13 Nm (1.3 m
kg, 9.4 ft
lb)
30 Nm (3.0 m
kg, 22 ft
lb)
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4-27
FRONT AND REAR BRAKESCHAS
NOTE:
NOTE:
NOTE:
EAS00588
DISASSEMBLING THE FRONT BRAKE
MASTER CYLINDER
Before disassembling the front brake master
cylinder, drain the brake fluid from the entire
brake system.
1. Disconnect:

brake light switch connector
1
(from the brake light switch)
2. Remove:

union bolt
2

copper washers 3

brake hose 4
To collect any remaining brake fluid, place a
container under the master cylinder and the end
of the brake hose.
3. Remove :

brake master cylinder bracket

brake master cylinder assembly
4. Remove :

dust boot

circlip
EAS00589
DISASSEMBLING THE REAR BRAKE
MASTER CYLINDER
1. Remove:

union bolt
1

copper washers 2

brake hose 3
To collect any remaining brake fluid, place a
container under the master cylinder and the end
of the brake hose.
2. Remove :

brake master cylinder assembly
3. Remove :

dust boot

circlip
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