2004 YAMAHA YZF-R1SC lock

2-21
TIGHTENING TORQUESSPEC
NOTE 1:
NOTE 2:
ItemFastenerThreadQ’tyTightening torqueRemarksItemFastenersizeQtyNmm
kgft
lbRemarks
Main axle bearing housingBoltM63121.28.7
Shift fork shaft stopperBoltM62101.07.2
Stopper screwScrewM81222.216
Shift rod lock nut (rear)NutM6170.75.0Left thread
Shift rod lock nut (front)NutM6170.75.0
Shift rod jointBoltM61101.07.2
Shift armBoltM61101.07.2
E.C.U.ScrewM6270.75.0
Neutral switch—M101202.015
EXUP servo motor coverScrewM5220.21.5
Coolant temperature sensor—M121181.813
Cylinder identification sensorBoltM6180.85.7
Atmospheric pressure sensorScrewM5270.75.0
Crankshaft position sensorBoltM61101.07.2
Oil level switchBoltM62101.07.2
1. First, tighten the bolts to approximately 19 Nm (1.9 m
kg, 14 ft
lb) with a torque wrench following the
tightening order.
2. Retighten the bolts 67 Nm (6.7 m
kg, 48 ft
lb) with a torque wrench.
1. First, tighten the bolts to approximately 20 Nm (2.0 m
kg, 15 ft
lb) with a torque wrench following the
tightening order.
2. Loosen the all bolts one by one following the tightening order and then tighten them to 20 Nm (2.7
m
kg, 15 ft
lb) again.
3. Retighten the bolts further to reach the specified angle (60).
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2-23
TIGHTENING TORQUESSPEC
See NOTE 2 CHASSIS TIGHTENING TORQUES
ItemThreadTighteningRemarksItemsizeNmm
kgft
lbRemarks
Upper bracket and outer tubeM8262.619
Upper bracket and steering stem nutM2811 311.382
Handlebar and outer tubeM8171.712
Handlebar and upper bracketM6131.39
Steering shaft and ring nutM30181.813See NOTE 1
Outer tube and under bracketM8232.317
Main switch and upper bracketM8262.619
Front brake master cylinder cap stopperM41.20.120.9
Front brake hose union boltsM10303.022
Front brake master cylinder and bracketM6131.39
Meter assembly and front cowling stay—1.30.130.9
Headlight and front cowling stay—0.80.080.6
Front cowling and headlight assembly—1.50.151.1
Cover 7, 8 and frameM650.53.6
Under cowling and engineM650.53.6
Windshield and front cowlingM50.40.040.3
Duct and console panelM51.30.130.9
End grip and handlebarM640.42.9
Horn bracket and under bracketM640.42.9
Coolant reservoir tank and frameM650.53.6
Engine mount front (left and right)M10454.533
Engine mount rear upperM10515.137
Engine mount rear underM10515.137
Engine mount rear adjust boltM1670.75.1
Catalyst pipe stay and frameM10444.432
Clutch cable lock nut (engine side)M870.75.1
Main frame and rear frameM10414.130
Throttle cable adjust nut (throttle body side)M650.53.6
Cover 2 and plate—0.80.080.6
Pivot shaft and nutM1810510.576
Connecting rod and frameM10444.432
Relay arm and connecting rodM10444.432
Relay arm and swingarmM10444.432
Rear shock absorber and relay armM10444.432
Rear shock absorber and upper bracketM10444.432
Upper bracket and frameM14929.267
Seal guardM670.75.1
Drive chain caseM670.75.1
Chain puller adjust nutM8161.612
Fuel tank and fuel pump assemblyM540.42.9
Fuel tank stay (front side) and frameM670.75.1
Fuel tank and fuel tank stay (front side)M670.75.1
Fuel tank stay (rear side) and rear frameM670.75.1
Side cover and fuel tankM50.40.040.3
Rider seat and frameM670.75.1
Seat lock plate and rear frameM6101.07
Side cover (rear side) and frameM540.42.9
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2-26
LUBRICATION POINTS AND LUBRICANT TYPESSPEC
EAS00032
CHASSIS
Lubrication point
Lubricant
Steering bearings and bearing races (upper and lower)
Throttle grip inner surface
Brake lever pivoting point and metal-to-metal moving parts
Clutch lever pivoting point and metal-to-metal moving parts
Engine mount bolts (rear upper and lower)
Relay arm, connecting rod and rear shock absorber collar
Pivot shaft
Swingarm pivot bearing
Swingarm head pipe end, oil seal and bush
Oil seal (relay arm, connecting arm and rear shock absorber)
Seat lock assembly moving parts
Sidestand pivoting pint and metal-to-metal moving parts
Link and sidestand switch contact point
Sidestand hook and spring
Shift shaft joint
Front wheel oil seal (right and left)
Front axle shaft
Rear wheel oil seal
Rear wheel drive hub oil seal
Rear wheel drive hub mating surface
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2-43
33Throttle body side cap
34Mud guard
35Turn signal light lead
36License plate light lead
37Rear fender rib
38Speed sensor lead
39Rear brake light switch lead
40Rear frame
41Swingarm bracket
42Main fuse lead
43Starting circuit cut-off relay lead
44Turn signal light relay lead
45Starter relay lead
46Main fuse lead (To the battery
positive lead)
47Right handlebar switch lead
17Battery negative lead
18Starter motor lead
19A.C.magneto lead
20Oil level switch lead
21Sidestand switch lead
22Throttle body lead
23Coolant reservoir tank drain hose
24Fuel tank drain hose
25Cover 7
26Radiator fan motor lead (left)
27Radiator fan motor lead (right)
28Wire harness
29Pipe 3
30Frame
31Coolant reservoir tank hose
32Thermo stat assembly breather
hose
CABLE ROUTINGSPEC
1Heat protector
2Crankshaft position sensor lead
3Neutral switch lead
4Ground lead
5Coolant reservoir tank
6Battery positive lead
7Starter relay
8Turn signal relay
9Main fuse
10Lean angle cut-off switch
11Atmospheric pressure sensor
12Tail / brake light lead
13Rear fender
14Seat lock cable
15Anti safety alarm coupler
16Starting circuit cut-off relay
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3-12
ADJUSTING THE VALVE CLEARANCE
CHK
ADJ
NOTE:
NOTE:
4. Measure:

valve clearance
Out of specification
Adjust.
Valve clearance (cold)
Intake valve
0.11  0.20 mm
(0.0043  0.0079 in)
Exhaust valve
0.21  0.25 mm
(0.0083  0.0098 in)
a. Turn the crankshaft counterclockwise.
b. When piston #1 is at TDC on the compres-
sion stroke, align the TDC mark
a on the
pickup rotor with the crankcase mating sur-
face
b.
TDC on the compression stroke can be found
when the camshaft lobes are turned away from
each other.
c. Measure the valve clearance with a thick-
ness gauge
1.

If the valve clearance is incorrect, record the
measured reading.

Measure the valve clearance in the following
sequence.
Valve clearance measuring sequence
Cylinder #1
#2
#4
#3
AFront
d. To measure the valve clearances of the other
cylinders, starting with cylinder #1 at TDC,
turn the crankshaft counterclockwise as spe-
cified in the following table.
BDegrees that the crankshaft is turned counter-
clockwise
CCylinder
DCombustion cycle
Cylinder #2180
Cylinder #4360
Cylinder #3540
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3-15
ADJUSTING THE VALVE CLEARANCE
CHK
ADJ
NOTE:

Refer to “ASSEMBLING AND ADJUSTING
THE ENGINE – CYLINDER HEAD AND CAM-
SHAFT” in chapter 5.

Lubricate the camshaft bearings, camshaft
lobes and camshaft journals.

First, install the exhaust camshaft.

Align the camshaft marks with the camshaft
cap marks.

Turn the crankshaft counterclockwise several
full turns to seat the parts.
g. Measure the valve clearance again.
h. If the valve clearance is still out of specifica-
tion, repeat all of the valve clearance adjust-
ment steps until the specified clearance is
obtained.
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3-19
SYNCHRONIZING THE THROTTLE BODIES /
ADJUSTING THE EXHAUST GAS VOLUMECHK
ADJ
NOTE:
NOTE: 9. Measure:

engine idling speed
Out of specification
Adjust.
Make sure that the vacuum pressure is within
specification.
10. Stop the engine and remove the measuring
equipment.
11. Adjust:

throttle cable free play
Refer to “ADJUSTING THE THROTTLE
CABLE FREE PLAY”.
Throttle cable free play
(at the flange of the throttle grip)
3  5 mm (0.12  0.20 in)
13. Install:

synchronizing hoses

fuel tank
Refer to “FUEL TANK”.

rider seat
Refer to “SEATS”.
ADJUSTING THE EXHAUST GAS VOLUME
Be sure to set the carbon monoxide density to
standard, and then adjust the exhaust gas.
1. Turn the main switch to “OFF” and engine
stop switch “ON”.
2. While keeping the “SELECT” and “RESET”
buttons pressed simultaneously, turn “ON”
the main switch (keep them pressed for 8 se-
conds or more).
All indications on the meter disappear except
the clock and trip indications.
Letters “dIAG” appear on the clock LCD.
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3-20
ADJUSTING THE EXHAUST GAS VOLUME
CHK
ADJ
NOTE:
NOTE: 3. Using the “SELECT” button, select either the
Co adjustment mode
1 (which appears as
“Co”) or the diagnosis mode (which appears
as “dIAG”).
4. After “Co” appears as a result of pressing the
“SELECT” button, simultaneously press the
“SELECT” and “RESET” buttons for 2 se-
conds or more to excute the selection.
5. Press the “SELECT” and “RESET” buttons to
select the cylinder
2.

The adjustment cylinder appears on the clock
LCD.
“RESET” button = decrement
“SELECT” button = increment
6. Excute the selection of the cylinder by simul-
taneously pressing the “SELECT” and “RE-
SET” buttons for approximately 2 seconds.
7. After selecting the adjustment cylinder,
change the “Co” adjustment volume by
pressing the “SELECT” and “RESET” but-
tons.
The Co adjustment volume appears on the trip
LCD.
“RESET” button = decrement
“SELECT” button = increment
8. The selection is executed upon releasing the
finger from the switch.
9. Simultaneously press the “SELECT” and
“RESET” buttons to return to the cylinder
selection. (step 5)
10. Cancel the mode by turning “OFF” the main
switch.
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