2004 YAMAHA YZF-R1SC remove seats

3-32
ADJUSTING THE CLUTCH CABLE FREE PLAY /
REPLACING THE AIR FILTER ELEMENTCHK
ADJ
a
b
NOTE: Engine side
a. Loosen the locknut
1.
b. Turn the adjusting nut
2 in direction a or b
until the specified clutch cable free play is ob-
tained.
Direction
Clutch cable free play is
increased.
DirectionClutch cable free play is
decreased.
c. Tighten the locknuts.
Lock nut
7Nm (0.7 m
kg, 5.1 ft
lb)
EAS00086
REPLACING THE AIR FILTER ELEMENT
1. Remove:

rider seat
Refer to “SEATS”.

fuel tank
Refer to “FUEL TANK”.
2. Remove:

air filter case cover
1
3. Check:

air filter element
1
Damage
Replace.
Replace the air filter element at periodic inter-
vals of 40,000 km travel.
The air filter needs more frequent service if you
are riding in unusuallu wet or dusty areas.
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3-33
REPLACING THE AIR FILTER ELEMENT /
CHECKING THE FUEL AND BREATHER HOSESCHK
ADJ
CAUTION:
NOTE:
NOTE: 4. Install:

air filter case cover
Never operate the engine without the air fil-
ter element installed. Unfiltered air will
cause rapid wear of engine parts and may
damage the engine. Operating the engine
without the air filter element will also affect
the throttle bodies tuning, leading to poor
engine performance and possible overheat-
ing.
When installing the air filter element into the air
filter case cover, make sure their sealing sur-
faces are aligned to prevent any air leaks.
5. Install:

fuel tank
Refer to “FUEL TANK”.

rider seat
Refer to “SEATS”.
EAS00096
CHECKING THE FUEL AND BREATHER
HOSES
The following procedure applies to all of the fuel
and breather hoses.
1. Remove:

rider seat
Refer to “SEATS”.

fuel tank
Refer to “FUEL TANK”.
2. Check:

breather hose
1

fuel hose 2
Cracks / damage
Replace.
Loose connection
Connect properly.
Before removing the fuel hoses, place a few
rags in the area under where it will be removed.
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3-34
CHECKING THE FUEL AND BREATHER HOSES /
CHECKING THE CRANKCASE BREATHER HOSECHK
ADJ
CAUTION:
CAUTION:
CAUTION:
3. Install:

fuel tank
Refer to “FUEL TANK”.

rider seat
Refer to “SEATS”.
To install the fuel tank, check that the breath-
er hose is not folded or pinched by the fuel
tank.
EAS00098
CHECKING THE CRANKCASE BREATHER
HOSE
1. Remove:

rider seat
Refer to “SEATS”.

fuel tank
Refer to “FUEL TANK”.
2. Check:

crankcase breather hose
1
Cracks / damage
Replace.
Loose connection
Connect properly.
Make sure the crankcase breather hose is
routed correctly.
3. Install:

fuel tank
Refer to “FUEL TANK”.

rider seat
Refer to “SEATS”.
To install the fuel tank, check that the breath-
er hose is not folded or pinched by the fuel
tank.
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3-39
CHANGING THE COOLANT
CHK
ADJ
CAUTION:
EAS00105
CHANGING THE COOLANT
1. Remove:

bottom cowlings

side cowlings
Refer to “COWLINGS”.

rider seat
Refer to “SEATS”.
2. Remove:

coolant reservoir tank

coolant reservoir hose
3. Disconnect:

coolant reservoir cap
1
4. Drain:

coolant
(from the coolant reservoir tank)
5. Remove:

radiator cap
1
A hot radiator is under pressure. Therefore,
do not remove the radiator cap when the en-
gine is hot. Scalding hot fluid and steam may
be blown out, which could cause serious in-
jury. When the engine has cooled, open the
radiator cap as follows:
Place a thick rag or a towel over the radiator
cap and slowly turn the radiator cap coun-
terclockwise toward the detent to allow any
residual pressure to escape. When the his-
sing sound has stopped, press down on the
radiator cap and turn it counterclockwise to
remove.
The following procedure applies to all of the
coolant drain bolts and copper washers.
6. Remove:

coolant drain bolts
1
(along with the copper washers)
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3-63
Relationship between the open-circuit voltage
and the charging time at 20C
Open-circuit voltage (V)
These values vary with the temperature, the condition of
the battery plates, and the electrolyte level. 13.0
12.5
12.0
11.5
5 6.5 10
Charging time (hours)
Ambient
temperature
20C
Open-circuit voltage (V)
Charging condition of the battery (%)
CHECKING AND CHARGING THE BATTERY
CHK
ADJ
NOTE:
CAUTION:
NOTE:
Since MF batteries are sealed, it is not possible
to check the charge state of the battery by mea-
suring the specific gravity of the electrolyte.
Therefore, the charge of the battery has to be
checked by measuring the voltage at the battery
terminals.
1. Remove:

rider seat
Refer to “SEATS”.
2. Disconnect:

battery leads
(from the battery terminals)
First, disconnect the negative battery lead
1, and then the positive battery lead 2.
3. Remove:

battery
4. Check:

battery charge
a. Connect a pocket tester to the battery termi-
nals.
Pocket tester
90890-03112, YU-3112
Positive tester probe

positive battery terminal
Negative tester probe

negative battery terminal

The charge state of an MF battery can be
checked by measuring its open-circuit voltage
(i.e., the voltage when the positive battery ter-
minal is disconnected).

No charging is necessary when the open-cir-
cuit voltage equals or exceeds 12.8 V.
b. Check the charge of the battery, as shown in
the charts and the following example.
Example
c. Open-circuit voltage = 12.0 V
d. Charging time = 6.5 hours
e. Charge of the battery = 20
30%
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3-67
CHECKING AND CHARGING THE BATTERY /
CHECKING THE FUSESCHK
ADJ
CAUTION:
CAUTION:
NOTE: 6. Install:

battery
7. Connect:

battery leads
(to the battery terminals)
First, connect the positive battery lead
1,
and then the negative battery lead
2.
8. Check:

battery terminals
Dirt
Clean with a wire brush.
Loose connection
Connect properly.
9. Lubricate:

battery terminals
Recommended lubricant
Dielectric grease
10. Install:

rider seat
Refer to “SEATS”.
EAS00181
CHECKING THE FUSES
The following procedure applies to all of the
fuses.
To avoid a short circuit, always set the main
switch to “OFF” when checking or replacing
a fuse.
1. Remove:

front cowling inner panel (left)
Refer to “COWLINGS”.

rider seat
Refer to “SEATS”.
2. Check:

fuse
a. Connect the pocket tester to the fuse and
check the continuity.
Set the pocket tester selector to “Ω  1”.
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5-2
5
Order Job / Part Q’ty Remarks
1
2
3
4
5
6
7
8
9
10Removing the exhaust pipe
Rider seat and passenger seat
Fuel tank
Side cowlings and bottom cowlings
EXUP pulley cover
EXUP cable
Exhaust pipe assembly
Exhaust pipe gasket
Exhaust valve pipe gasket
Exhaust valve pipe assembly
Catalyst pipe assembly
Gasket
Muffler
Gasket1
2
1
4
1
1
1
1
2
2Remove 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.
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)
20 Nm (2.0 m
kg, 14 ft
lb)
20 Nm (2.0 m
kg, 14 ft
lb)
20 Nm (2.0 m
kg, 14 ft
lb)
23 Nm (2.3 m
kg, 17 ft
lb)
ENGINEENG
EXHAUST PIPE
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5-23
CYLINDER HEADENG
NOTE:
NOTE:
NOTE:
EAS00222
REMOVING THE CYLINDER HEAD
1. Remove:

intake camshaft

exhaust camshaft
Refer to “REMOVING THE CAMSHAFTS”.
2. Remove:

cylinder head nuts

cylinder head bolts

Loosen the nuts in the proper sequence as
shown.

Loosen each nut 1 / 2 of a turn at a time. After all
of the nuts are fully loosened, remove them.
EAS00227
CHECKING THE CYLINDER HEAD
1. Eliminate:

combustion chamber carbon deposits
(with a rounded scraper)
Do not use a sharp instrument to avoid damag-
ing or scratching:

spark plug bore threads

valve seats
2. Check:

cylinder head
Damage / scratches
Replace.
3. Measure:

cylinder head warpage
Out of specification
Resurface the cylin-
der head.
Maximum cylinder head warpage
0.10 mm (0.0039 in)
a. Place a straightedge
1 and a thickness
gauge
2 across the cylinder head.
b. Measure the warpage.
c. If the limit is exceeded, resurface the cylinder
head as follows.
d. Place a 400
600 grit wet sandpaper on the
surface plate and resurface the cylinder
head using a figure-eight sanding pattern.
To ensure an even surface, rotate the cylinder
head several times.
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