Yamaha YZF-R1SC Motorcycle Maintenance Manuals

Manuals and User Guides for Yamaha YZF-R1SC Motorcycle Maintenance. We have 1 Yamaha YZF-R1SC Motorcycle Maintenance manual available for free PDF download: Service Manual

Yamaha YZF-R1SC Service Manual (457 pages)

YZF-R1S; YZF-R1SC Motorcycle

Brand: Yamaha | Category: Motorcycle | Size: 21 MB

Specifications

5
- Table of Contents
  6
Important Manual Information
3
How to Use this Manual
4
Periodic Checks and Adjustments

5
Chassis

5
Engine

5
Cooling System

5
Fuel Injection System

5
Electrical System

5
Troubleshooting

15
Chapter 1 General Information

17
Motorcycle Identification

17
- Vehicle Identification Number
  17
- Model Label
  17
Gen Info

17
Features

18
- Instrument Functions
  18
Important Information

22
- Preparation for Removal and Disassembly
  22
- Replacement Parts
  22
- Gaskets, Oil Seals and O-Rings
  22
- Lock Washers/Plates and Cotter Pins
  23
- Bearings and Oil Seals
  23
- Circlips
  23
Checking the Connections

24
Special Tools

25
Chapter 2 Specifications

29
Spec

29
General Specifications

29
Engine Specifications

30
Chassis Specifications

39
Electrical Specifications

43
Conversion Table

46
General Tightening Torque Specifications

46
Tightening Torques

47
- Engine Tightening Torques
  47
- Chassis Tightening Torques
  51
Lubrication Points and Lubricant Types

53
- Engine
  53
- Chassis
  54
Cooling System Diagrams

55
Engine Oil Lubrication Chart

57
Lubrication Diagrams

58
Cable Routing

63
Chapter 3 Periodic Checks and Adjustments

78
Introduction

78
Periodic Maintenance Chart for the Emission Control System

78
General Maintenance and Lubrication Chart

78
- Air Filter
  79
Chk Adj

78
Seats

80
Fuel Tank

81
- Removing the Fuel Tank
  82
- Removing the Fuel Pump
  82
- Installing the Fuel Pump
  83
- Installing the Fuel Tank
  83
Cowlings

84
- Front Cowling and Side Cowlings
  84
- Rear Cowling
  85
- Removal
  86
- Installation
  86
Air Filter Case

87
Engine

88
- Adjusting the Valve Clearance
  88
- Synchronizing the Throttle Bodies
  94
- Adjusting the Exhaust Gas Volume
  96
- Adjusting the Engine Idling Speed
  98
- Adjusting the Throttle Cable Free Play
  99
- Checking the Spark Plugs
  100
- Measuring the Compression Pressure
  101
- Checking the Engine Oil Level
  103
- Changing the Engine Oil
  105
- Measuring the Engine Oil Pressure
  106
- Adjusting the Clutch Cable Free Play
  108
- Replacing the Air Filter Element
  109
- Checking the Fuel and Breather Hoses
  110
- Checking the Crankcase Breather Hose
  111
- Checking the Exhaust System
  112
- Adjusting the Exup Cables
  113
- Checking the Coolant Level
  114
- Checking the Cooling System
  115
- Changing the Coolant
  116
Chassis

119
- Adjusting the Front Brake
  119
- Adjusting the Rear Brake
  120
- Checking the Brake Fluid Level
  121
- Adjusting the Rear Brake Light Switch
  122
- Checking the Front and Rear Brake Pads
  122
- Checking the Front and Rear Brake Hoses
  123
- Bleeding the Hydraulic Brake System
  124
- Adjusting the Shift Pedal
  125
- Adjusting the Drive Chain Slack
  126
- Lubricating the Drive Chain
  127
- Checking and Adjusting the Steering Head
  128
- Checking the Front Fork
  130
- Adjusting the Front Fork Legs
  131
- Adjusting the Rear Shock Absorber Assembly
  133
- Checking the Tires
  135
- Checking the Wheels
  137
- Checking and Lubricating the Cables
  138
- Lubricating the Levers and Pedals
  138
- Lubricating the Sidestand
  138
- Lubricating the Rear Suspension
  138
Electrical System

139
- Checking and Charging the Battery
  139
- Checking the Fuses
  144
- Replacing the Headlight Bulbs
  146
- Adjusting the Headlight Beams
  147
Chapter 4 Chassis

148
Chas

148
Front Wheel and Brake Discs

148
- Removing the Front Wheel
  150
- Checking the Front Wheel
  150
- Checking the Brake Discs
  152
- Installing the Front Wheel
  153
- Adjusting the Front Wheel Static Balance
  154
- Rear Wheel and Brake Disc
  156
Rear Wheel and Brake Disc Rear Wheel

156
Front and Rear Brakes

162
- Front Brake Pads
  162
- Rear Brake Pads
  163
- Replacing the Front Brake Pads
  165
- Replacing the Rear Brake Pads
  167
- Front Brake Master Cylinder
  169
- Cylinder
  172
- Disassembling the Rear Brake Master
  173
- Cylinder
  173
- Checking the Front and Rear Brake Master
  175
- Cylinders
  175
- Assembling and Installing the Front Brake
  176
- Master Cylinder
  176
- Assembling the Rear Brake Master Cylinder
  178
- Front Brake Calipers
  180
- Rear Brake Caliper
  182
- Disassembling the Front Brake Calipers
  184
- Calipers
  184
- Assembling and Installing the Rear
  189
- Brake Caliper
  189
Front Fork

191
- Front Fork Legs
  191
- Removing the Front Fork Legs
  194
- Disassembling the Front Fork Legs
  195
- Checking the Front Fork Legs
  196
- Assembling the Front Fork Legs
  197
- Installing the Front Fork Legs
  202
Handlebars

203
- Removing the Handlebars
  205
- Checking the Handlebars
  205
- Installing the Handlebars
  205
- Checking the Steering Damper
  207
Steering Head

208
- Under Bracket
  208
- Removing the under Bracket
  210
- Checking the Steering Head
  210
- Installing the Steering Head
  211
Rear Shock Absorber Assembly

212
Swingarm and Drive Chain

216
- Removing the Swingarm
  218
- Removing the Drive Chain
  219
- Checking the Swingarm
  219
- Checking the Drive Chain
  220
- Installing the Swingarm
  222
Chapter 5 Engine

223
- Drive Sprocket
  223
- Exhaust Pipe
  224
- Leads and Hoses
  227
- Engine
  227
- Installing the Engine
  231
Eng

223
Camshaft

233
- Cylinder Head Cover
  233
- Camshafts
  235
- Removing the Camshafts
  236
- Checking the Camshafts
  237
- Checking the Timing Chain, Camshaft Sprockets, and Timing Chain Guides
  239
- Checking the Timing Chain Tensioner
  239
- Installing the Camshafts
  241
Cylinder Head

244
- Removing the Cylinder Head
  245
- Checking the Cylinder Head
  245
- Installing the Cylinder Head
  246
Valves and Valve Springs

249
- Removing the Valves
  249
- Checking the Valves and Valve Guides
  250
- Checking the Valve Seats
  252
- Checking the Valve Springs
  253
- Checking the Valve Lifters
  254
- Installing the Valves
  254
Starter Clutch and Generator

257
- Stator Coil Assembly
  257
- Starter Clutch
  259
- Removing the Generator
  260
- Checking the Damper
  261
- Checking the Starter Clutch
  262
- Installing the Starter Clutch
  263
- Installing the Generator
  263
Crankshaft Position Sensor

265
- Removing the Crankshaft Position Sensor
  266
- Installing the Crankshaft Position Sensor
  266
Clutch

268
- Clutch Cover
  268
- Pull Lever Shaft
  269
- Clutch
  269
- Removing the Clutch
  272
- Checking the Friction Plates
  274
- Checking the Clutch Plates
  274
- Checking the Clutch Springs
  275
- Checking the Clutch Housing
  275
- Checking the Clutch Boss
  275
- Checking the Pressure Plate
  276
- Checking the Pull Lever Shaft and Pull Rod
  276
- Installing the Clutch
  276
Shift Shaft

280
- Shift Shaft and Stopper Lever
  280
- Removing the Shift Shaft
  282
- Checking the Shift Shaft
  283
- Checking the Stopper Lever
  283
- Installing the Shift Shaft
  283
Oil Pan and Oil Pump

285
- Removing the Oil Pan
  288
- Checking the Sprocket and Chain
  288
- Checking the Oil Pump
  289
- Checking the Relief Valve
  289
- Checking the Oil Delivery Pipe and Oil Pipe
  290
- Checking the Oil Strainer
  290
- Checking the Oil Nozzles
  290
- Assembling the Oil Pump
  290
- Installing the Oil/Water Pump Assembly
  291
- Installing the Oil Pan
  293
Crankcase

294
- Disassembling the Crankcase
  296
- Checking the Crankcase
  297
- Checking the Bearings and Oil Seals
  297
- Assembling the Crankcase
  297
Connecting Rods and Pistons

299
- Removing the Connecting Rods and Pistons
  300
- Removing the Crankshaft Assembly
  301
- Checking the Cylinder and Piston
  301
- Checking the Piston Rings
  302
- Checking the Piston Pins
  303
- Checking the Big End Bearings
  304
- Installing the Connecting Rod and Piston
  308
Crankshaft

314
Transmission

319
- Transmission, Shift Drum Assembly and Shift Forks
  319
- Removing the Transmission
  325
- Checking the Shift Forks
  325
- Checking the Shift Drum Assembly
  326
- Checking the Transmission
  326
- Installing the Transmission
  327
Chapter 6 Cooling System

329
Cool

329
Radiator

329
- Checking the Radiator
  331
- Installing the Radiator
  332
Oil Cooler

333
- Checking the Oil Cooler
  335
- Installing the Oil Cooler
  335
Thermostat

336
Water Pump

340
- Impeller Shaft
  340
- Disassembling the Water Pump
  342
- Checking the Water Pump
  342
Chapter 7 Fuel Injection System

345
- Wiring Diagram
  346
- Ecu's Self-Diagnostic Function
  348
- Fail-Safe Action
  349
- Fail-Safe Actions Table
  349
- Troubleshooting Chart
  351
- Diagnostic Mode
  352
- Troubleshooting Details
  359
Throttle Bodies

379
Air Induction System

390
- Air Injection
  390
- Air Cut-Off Valve
  390
- Air Induction System Diagrams
  390
- Checking the Air Induction System
  392
Chapter 8 Electrical System

394
Elec

394
Electrical Components

394
Checking Switch Continuity

396
Checking the Switches

397
Checking the Bulbs and Bulb Sockets

398
- Types of Bulbs
  398
- Checking the Condition of the Bulbs
  398
- Checking the Condition of the Bulb Sockets
  399
- CHECKING the Leds
  400
Ignition System

401
- Circuit Diagram
  401
- Troubleshooting
  403
Electric Starting System

407
- Circuit Diagram
  407
- Starting Circuit Cut-Off System Operation
  408
- Troubleshooting
  409
Starter Motor

412
- Checking the Starter Motor
  414
- Assembling the Starter Motor
  415
Charging System

417
- Circuit Diagram
  417
- Troubleshooting
  418
Lighting System

420
- Circuit Diagram
  420
- Troubleshooting
  422
- Checking the Lighting System
  424
Signaling System

427
- Circuit Diagram
  427
- Troubleshooting
  429
- Checking the Signaling System
  429
Cooling System

436
- Circuit Diagram
  436
- Troubleshooting
  438
Fuel Pump System

441
- Circuit Diagram
  441
- Troubleshooting
  443
- Checking the Fuel Pump
  445
Self-Diagnosis

446
- Troubleshooting
  449
Chapter 9

449
- Engine
  449
- Fuel System
  449
- Electrical Systems
  449
Starting Failures

449
Incorrect Engine Idling Speed

450
- Engine
  450
- Fuel System
  450
- Electrical Systems
  450
Poor Medium-And-High-Speed Performance

450
Trbl Shtg

450
Faulty Gear Shifting

451
- Shifting Is Difficult
  451
- Shift Pedal Does Not Move
  451
- Jumps out of Gear
  451
Faulty Clutch

451
- Clutch Slips
  451
- Clutch Drags
  451
Overheating

452
- Engine
  452
- Cooling System
  452
- Fuel System
  452
- Chassis
  452
- Electrical Systems
  452
Overcooling

452
Poor Braking Performance

452
Faulty Front Fork Legs

453
- Leaking Oil
  453
- Malfunction
  453
Unstable Handling

453
Faulty Lighting or Signaling System

454
- Headlight Does Not Come on
  454
- Headlight Bulb Burnt out
  454
- Tail/Brake Light Does Not Come on
  454
- Tail/Brake Light Bulb Burnt out
  454
- Turn Signal Does Not Come on
  454
- Turn Signal Blinks Slowly
  454
- Turn Signal Remains Lit
  454
- Turn Signal Blinks Quickly
  454
- Horn Does Not Sound
  454

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Yamaha YZF-R1SC Service Manual (457 pages)

Table of Contents

Specifications

Periodic Checks and Adjustments

Chassis

Engine

Cooling System

Fuel Injection System

Electrical System

Troubleshooting

Chapter 1 General Information

Motorcycle Identification

Gen Info

Features

Important Information

Checking the Connections

Special Tools

Chapter 2 Specifications

Spec

General Specifications

Engine Specifications

Chassis Specifications

Electrical Specifications

Conversion Table

General Tightening Torque Specifications

Tightening Torques

Lubrication Points and Lubricant Types

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

Chk Adj

Seats

Fuel Tank

Cowlings

Air Filter Case

Engine

Chassis

Electrical System

Chapter 4 Chassis

Chas

Front Wheel and Brake Discs

Rear Wheel and Brake Disc Rear Wheel

Front and Rear Brakes

Front Fork

Handlebars

Steering Head

Rear Shock Absorber Assembly

Swingarm and Drive Chain

Chapter 5 Engine

Eng

Camshaft

Cylinder Head

Valves and Valve Springs

Starter Clutch and Generator

Crankshaft Position Sensor

Clutch

Shift Shaft

Oil Pan and Oil Pump

Crankcase

Connecting Rods and Pistons

Crankshaft

Transmission

Chapter 6 Cooling System

Cool

Radiator

Oil Cooler

Thermostat

Water Pump

Chapter 7 Fuel Injection System

Throttle Bodies

Air Induction System

Chapter 8 Electrical System

Elec

Electrical Components