2004-2005 Yamaha YZF-R1, YZF-R1 S, YZF-R1 SC service manual

Product Information

Table of Contents

CHAPTER 1
GENERAL INFORMATION

• Motorcycle Identification
  • Vehicle Identification Number
  • Model Label
• Features
  • Instrument Functions
• Important Information
  • Preparation for Removal and Disassembly
  • Replacement Parts
  • Gaskets, Oil Seals and O-rings
  • Lock Washers/Plates and Cotter Pins
  • Bearings and Oil Seals
  • Circlips
• Checking the Connections
• Special Tools

CHAPTER 2
SPECIFICATIONS

• General Specifications
• Engine Specifications
• Chassis Specifications
• Electrical Specifications
• Conversion Table
• General Tightening Torque Specifications
  • Engine Tightening Torques
  • Chassis Tightening Torques
• Lubrication Points and Lubricant Types
  • Engine
  • Chassis
• Cooling System Diagrams
• Engine Oil Lubrication Chart
• Lubrication Diagrams
• Cable Routing

CHAPTER 3
PERIODIC CHECKS AND ADJUSTMENTS

• Introduction
• Periodic Maintenance Chart for the Emission Control System
• General Maintenance and Lubrication Chart
• Seats
• Fuel Tank
  • Removing the Fuel Tank
  • Removing the Fuel Pump
  • Installing the Fuel Pump
  • Installing the Fuel Tank
• Cowling
  • Front Cowling and Side Cowlings
  • Rear Cowling
  • Removal
  • Installation
• Air Filter Case
• Engine
  • Adjusting the Valve Clearance
  • Synchronizing the Throttle Bodies
  • Adjusting the Engine Idling Speed
  • Adjusting the Throttle Cable Free Play
  • Checking the Spark Plugs
  • Measuring the Compression Pressure
  • Checking the Engine Oil Pressure
  • Changing the Engine Oil
  • Checking the Coolant Level
  • Checking the Cooling System
  • Changing the Coolant
• Chassis
  • Adjusting the Front Brake
  • Adjusting the Rear Brake
  • Checking the Brake Fluid Level
  • Adjusting the Brake Light Switch
  • Checking the Front and Rear Brake Pads
  • Checking the Front and Rear Brake Hoses
  • Adjusting the Drive Chain
  • Checking and Lubricating the Cables
  • Checking the Steering
  • Checking the Wheel Bearings
  • Checking the Sidestand
  • Lubricating the Sidestand
  • Lubricating the Rear Suspension
• Electrical System
  • Checking and Charging the Battery
  • Checking the Fuses
  • Replacing the Headlight Bulbs
  • Adjusting the Headlight Beam

CHAPTER 4
CHASSIS

• Front Wheel and Brake Discs
  • Front Wheel
  • Removing the Front Wheel
  • Checking the Brake Discs
  • Checking the Front Wheel Bearings
  • Installing the Front Wheel
  • Adjusting the Front Wheel Static Balance
• Rear Wheel and Brake Disc
  • Rear Wheel
  • Removing the Rear Wheel
  • Checking the Rear Wheel Drive Hub
  • Checking and Replacing the Rear Wheel Sprocket
  • Installing the Rear Wheel
  • Adjusting the Rear Wheel Static Balance
• Front and Rear Brakes
  • Front Brake Pads
  • Replacing the Front Brake Pads
  • Checking the Front Brake Fluid Level
  • Front Brake Master Cylinder
  • Replacing the Front Brake Master Cylinder
  • Disassembling and Installing the Front Brake Calipers
  • Checking the Front Brake Caliper
  • Installing the Front Brake Caliper
• Rear Brake Pads
  • Replacing the Rear Brake Pads
  • Checking the Rear Brake Fluid Level
  • Rear Brake Master Cylinder
  • Replacing the Rear Brake Master Cylinder
  • Disassembling and Installing the Rear Brake Calipers
  • Checking the Rear Brake Caliper
  • Installing the Rear Brake Caliper
• Front Fork
  • Removing the Front Fork Legs
  • Disassembling the Front Fork Legs
  • Checking the Front Fork Legs
  • Assembling and Installing the Front Fork Legs
• Handlebars
  • Removing the Handlebars
  • Checking the Handlebars
  • Installing the Handlebars
• Steering Head
  • Checking the Lower Bracket
  • Checking the Steering Head
  • Installing the Steering Head
• Rear Shock Absorber Assembly
  • Handling the Rear Shock Absorber
  • Adjusting the Rear Shock Absorber Assembly
  • Checking the Rear Shock Absorber Assembly
  • Installing the Rear Shock Absorber Assembly
• Swingarm and Drive Chain
  • Removing the Swingarm
  • Checking the Swingarm
  • Installing the Swingarm
  • Checking the Drive Chain
  • Installing the Drive Chain

CHAPTER 5
ENGINE

• Engine
  • Drive Sprocket
  • Exhaust Pipe
  • Engine
  • Engine Hoses
  • Installing the Engine
• Camshaft
  • Cylinder Head Cover
  • Camshaft
  • Adjusting the Camshaft
  • Checking the Timing Chain, Camshaft Sprockets, and Timing Chain Tensioner
  • Checking the Timing Chain Tensioner
  • Installing the Camshafts
• Cylinder Head
  • Removing the Cylinder Head
  • Checking the Cylinder Head
  • Installing the Cylinder Head
• Valves and Valve Springs
  • Removing the Valves
  • Checking the Valves and Valve Guides
  • Checking the Valve Seats
  • Checking the Valve Springs
  • Installing the Valves

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