2004 YAMAHA YZF-R1SC fuel tank removal

LUBRICATION DIAGRAMS2-30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CABLE ROUTING2-35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHAPTER 3
PERIODIC CHECKS AND ADJUSTMENTS
INTRODUCTION3-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PERIODIC MAINTENANCE CHART FOR THE EMISSION
CONTROL SYSTEM3-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL MAINTENANCE AND LUBRICATION CHART3-1 . . . . . . . . .
SEATS3-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FUEL TANK3-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE FUEL TANK 3-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE FUEL PUMP 3-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE FUEL PUMP 3-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE FUEL TANK 3-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
COWLINGS3-7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FRONT COWLING AND SIDE COWLINGS 3-7. . . . . . . . . . . . . . . . . . .
REAR COWLING 3-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVAL 3-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLATION 3-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AIR FILTER CASE3-10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE3-11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ADJUSTING THE VALVE CLEARANCE 3-11. . . . . . . . . . . . . . . . . . . . . .
SYNCHRONIZING THE THROTTLE BODIES 3-17. . . . . . . . . . . . . . . . .
ADJUSTING THE EXHAUST GAS VOLUME 3-19. . . . . . . . . . . . . . . . . .
ADJUSTING THE ENGINE IDLING SPEED 3-21. . . . . . . . . . . . . . . . . . .
ADJUSTING THE THROTTLE CABLE FREE PLAY 3-22. . . . . . . . . . . .
CHECKING THE SPARK PLUGS 3-23. . . . . . . . . . . . . . . . . . . . . . . . . . . .
MEASURING THE COMPRESSION PRESSURE 3-24. . . . . . . . . . . . . .
CHECKING THE ENGINE OIL LEVEL 3-26. . . . . . . . . . . . . . . . . . . . . . . .
CHANGING THE ENGINE OIL 3-28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MEASURING THE ENGINE OIL PRESSURE 3-29. . . . . . . . . . . . . . . . .
ADJUSTING THE CLUTCH CABLE FREE PLAY 3-31. . . . . . . . . . . . . . .
REPLACING THE AIR FILTER ELEMENT 3-32. . . . . . . . . . . . . . . . . . . .
CHECKING THE FUEL AND BREATHER HOSES 3-33. . . . . . . . . . . . .
CHECKING THE CRANKCASE BREATHER HOSE 3-34. . . . . . . . . . . .
CHECKING THE EXHAUST SYSTEM 3-35. . . . . . . . . . . . . . . . . . . . . . . .
ADJUSTING THE EXUP CABLES 3-36. . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE COOLANT LEVEL 3-37. . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE COOLING SYSTEM 3-38. . . . . . . . . . . . . . . . . . . . . . . .
CHANGING THE COOLANT 3-39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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3-4
Order Job / Part Q’ty Remarks
1
2
3
4
5
6
7
8
9
10
11Removing the fuel tank
Rider sear
Fuel tank side cover
Fuel hose connector cover
Fuel hose
Fuel return hose
Fuel sender coupler
Fuel pump coupler
Fuel tank over flow hose
Fuel tank breather hose
Fuel tank
Fuel tank cover
Fuel pump2
1
1
1
1
1
1
1
1
1
1Remove the parts in the order listed.
Refer to “SEATS”.
Disconnect.
Disconnect.
Disconnect.
Disconnect.
Disconnect.
Disconnect.
Disconnect.
For installation, reverse the removal
procedure.
10 Nm (1.0 m
kg, 7.2 ft
lb)
10 Nm (1.0 m
kg, 7.2 ft
lb)
4 Nm (0.4 m
kg, 2.9 ft
lb)
4 Nm (0.4 m
kg, 2.9 ft
lb)
FUEL TANK
CHK
ADJ
EAS00040
FUEL TANK
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3-10
Order Job / Part Q’ty Remarks
1
2
3
4
5
6
7
8
9
10Removing the air filter case
Rider sear
Fuel tank
Plug
Air temperature sensor lead coupler
Spacer
Air temperature sensor
Air filter case cover
Air filter
Funnel
Air filter case
Air induction system hose
Crankcase breather hose1
1
1
1
1
1
2
1
1
1Remove the parts in the order listed.
Refer to “SEATS”.
Refer to “FUEL TANK”.
Disconnect.
Disconnect.
Disconnect.
For installation, reverse the removal
procedure.
2 Nm (0.2 m
kg, 1.4 ft
lb)
3.4 Nm (0.34 m
kg, 2.5 ft
lb)
AIR FILTER CASE
CHK
ADJ
AIR FILTER CASE
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3-17
ADJUSTING THE VALVE CLEARANCE /
SYNCHRONIZING THE THROTTLE BODIESCHK
ADJ
NOTE:
NOTE:
NOTE:
7. Install:

all removed parts
For installation, reverse the removal procedure.
SYNCHRONIZING THE THROTTLE BODIES
Prior to synchronizing the throttle bodies, the
valve clearance and the engine idling speed
should be properly adjusted and the ignition tim-
ing should be checked.
1. Stand the motorcycle on a level surface.
Place the motorcycle on a suitable stand.
2. Remove:

rider seat
Refer to “SEATS”.

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

synchronizing hoses
1
4. Install:

vacuum gauge
1
(onto the synchronizing hose)

digital tachometer
(near the spark plug)
Vacuum gauge
90890-03094, YU-08030
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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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6-8
Order Job / Part Q’ty Remarks
1
2
3
4
5Removing the thermostat assembly
Rider seat
Fuel tank
Air filter case
Coolant
Thermostat assembly outlet hose
Thermostat assembly breather hose
Thermostat assembly
Thermostat assembly inlet hose
Band1
1
1
1
2Remove the parts in the order listed.
Refer to “SEATS” in chapter 3.
Refer to “FUEL TANK” in chapter 3.
Refer to “AIR FILTER CASE” in chapter 3.
Drain.
Refer to “CHANGING THE COOLANT” in
chapter3.
For installation, reverse the removal
procedure.
THERMOSTATCOOL
EAS00460
THERMOSTAT
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8-19
STARTER MOTORELEC
Order Job / Part Q’ty Remarks
1
2Removing the starter motor
Seat
Fuel tank
Throttle body assembly
Starter motor lead
Starter motor1
1Remove the parts in the order listed.
Refer to “SEAT” in chapter 3.
Refer to “FUEL TANK” in chapter 3.
Refer to “THROTTLE BODIES” in
chapter 7.
For installation, reverse the removal
procedure.
10 Nm (1.0 m
kg, 7.2 ft
lb)5 Nm (0.5 m
kg, 3.6 ft
lb)
5 Nm (0.5 m
kg, 3.6 ft
lb)
EAS00767
STARTER MOTOR
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