Yamaha YZF-R1SC 2004-2006 Factory Service Repair Manual
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🏷️ Basic Information Identification Make: Yamaha Model: YZF-R1SC Model Variant: SC (Special Colour/Spec) Years Covered: 2004, 2005, 2006 Vehicle Type: Sportbike / Supersport Motorcycle Codes Chassis Code: RN09 👋 Introduction Market Position Market Segment: Hyperbike/Superbike, competing with liter-class sportbikes Competitive Analysis Key Competitors: Honda CBR954RR, Suzuki GSX-R1000 (K3/K4), Kawasaki ZX-10R (2004-2005), Ducati 999 Key Features Performance Focus: High horsepower, advanced aerodynamics, track-oriented handling Engine Design: Inline-four cylinder, DOHC, 5 valves per cylinder Chassis Design: Aluminum twin-spar frame for rigidity and light weight Suspension: Fully adjustable front forks and rear monoshock for precise tuning Braking System: Radial-mount front brake calipers for improved stopping power and feel Aerodynamics: Aggressive fairing design for reduced drag and improved stability at high speeds 📋 Manual Details Coverage Areas Primary Coverage: Complete Factory Service Repair Additional Coverage: Maintenance, Troubleshooting, Diagnostics, Repair, Overhaul Page Count Estimated Page Count: 500+ Manual Type Manual Type: Factory Service Manual / Workshop Manual Language Language: English Format Delivery Format: PDF Download 📖 Manual Coverage Systems Covered Engine: Complete engine assembly, internal components, valve train, ignition, fuel injection, lubrication, cooling Transmission: Clutch, gearbox internals, shift mechanism, lubrication Chassis And Suspension: Frame, front fork (telescopic), rear shock absorber (monoshock), swingarm, bearings Brakes: Front and rear disc brakes, caliper service, master cylinder, hydraulic lines, bleeding procedures Electrical System: Wiring diagrams, battery, charging system (stator, regulator/rectifier), lighting, starter motor, ECU, sensors, fuses Fuel System: Fuel pump, injectors, throttle body, sensors (TPS, MAP, IAT), fuel tank, lines Exhaust System: Catalytic converter (if applicable), mufflers, exhaust pipes Cooling System: Radiator, fan, coolant pump, thermostat, hoses, coolant specifications Bodywork And Fairings: Removal, installation, and component identification of all body panels Wheels And Tires: Wheel removal, tire mounting, balancing, specifications Procedures Included Maintenance: Scheduled maintenance, oil changes, filter replacements, chain adjustment, brake fluid changes, coolant flushes Troubleshooting: Diagnostic flowcharts for common and uncommon issues, fault codes (if applicable) Repair: Step-by-step instructions for component removal, repair, and reinstallation Rebuilds: Detailed procedures for engine and transmission rebuilds Diagnostics: Electrical system diagnostics, sensor testing, fuel system testing Adjustments: Carburetor/throttle body synchronization (if applicable), clutch lever, brake levers, suspension settings Technical Depth Depth: Comprehensive, from basic maintenance to full engine and transmission rebuilds Diagnostic Tools: Information on special tools required for specific repairs and diagnostics 📊 Manual Specifications File Format File Format: PDF Searchability: Likely text-searchable within the PDF Print Quality Print Readability: High quality for clear printing of diagrams and text Binding Type Binding Type: N/A (PDF Download) Paper Type Paper Type: N/A (PDF Download) ⚙️ Engine Specifications Primary Engine Engine Type: Liquid-cooled, 4-stroke, DOHC, inline four-cylinder Displacement: 998 cc Bore X Stroke: 74.0 mm x 57.0 mm Compression Ratio: 12.3:1 Valve Train: DOHC, 5 valves per cylinder Ignition System: TCI (Transistor Controlled Ignition) Performance Horsepower: Approx. 172 hp (at crank, depending on market/emissions) Torque: Approx. 110 Nm (at crank, depending on market) Fuel System Fuel Delivery: Fuel Injection with 40mm throttle bodies Fuel Type: Unleaded premium gasoline (95 RON or higher recommended) Lubrication System Oil Type: Yamalube 4 (or equivalent) 10W-40 API SG or higher Oil Capacity: Approx. 3.9 L (with filter change) 🔧 Transmission Standard Transmission Type: 6-speed constant mesh Clutch Type: Wet, multi-plate, assist and slipper clutch Features Gear Ratios: Detailed ratios available in manual, e.g., 1st: 2.750, 2nd: 2.063, 3rd: 1.700, 4th: 1.471, 5th: 1.333, 6th: 1.208 Final Drive: Chain drive 📐 Dimensions Exterior Overall Length: Approx. 2,085 mm (82.1 in) Overall Width: Approx. 705 mm (27.8 in) Overall Height: Approx. 1,135 mm (44.7 in) Seat Height: Approx. 835 mm (32.9 in) Wheelbase: Approx. 1,405 mm (55.3 in) Ground Clearance: Approx. 135 mm (5.3 in) Weights Dry Weight: Approx. 177 kg (390 lbs) Wet Weight: Approx. 205 kg (452 lbs) (fully fueled) Fuel Capacity: 18 L (4.75 US gal) 🛡️ Safety Features Ratings Safety Ratings: N/A (Motorcycle safety ratings differ from automotive, focus on design for rider safety) Active Features Braking System: Dual 320mm front discs with radial-mount 4-piston calipers, 220mm rear disc with 2-piston caliper Suspension Control: Adjustable suspension for optimal handling and stability Passive Features Frame Design: Rigid aluminum frame for predictable handling Lighting: Dual multi-reflector headlights for improved visibility 💡 Technology Features Infotainment Infotainment System: N/A (Sportbike focused, no infotainment in the modern sense) Driver Assistance Rider Aids: Assist and slipper clutch for smoother downshifts and reduced rear-wheel hop. Electronics: ECU controlled fuel injection and ignition timing for optimal performance across the rev range. Connectivity Connectivity Features: N/A (No Bluetooth or smartphone integration on this model) 🔧 Maintenance Service Intervals Oil Change Interval: Every 6,000 km (3,700 miles) or 6 months, whichever comes first (refer to manual for exact recommendation) Air Filter Inspection: Every 6,000 km (3,700 miles) Spark Plug Replacement: Every 18,000 km (11,000 miles) Coolant Replacement: Every 2 years or 24,000 km (15,000 miles) Brake Fluid Replacement: Every 2 years or 24,000 km...
Approx. 172 hp (at crank, depending on market/emissions)
Torque:
Approx. 110 Nm (at crank, depending on market)
Fuel System
Fuel Delivery:
Fuel Injection with 40mm throttle bodies
Fuel Type:
Unleaded premium gasoline (95 RON or higher recommended)
Lubrication System
Oil Type:
Yamalube 4 (or equivalent) 10W-40 API SG or higher
Oil Capacity:
Approx. 3.9 L (with filter change)
🔧 Transmission
Standard
Transmission Type:
6-speed constant mesh
Clutch Type:
Wet, multi-plate, assist and slipper clutch
Features
Gear Ratios:
Detailed ratios available in manual, e.g., 1st: 2.750, 2nd: 2.063, 3rd: 1.700, 4th: 1.471, 5th: 1.333, 6th: 1.208
Final Drive:
Chain drive
📐 Dimensions
Exterior
Overall Length:
Approx. 2,085 mm (82.1 in)
Overall Width:
Approx. 705 mm (27.8 in)
Overall Height:
Approx. 1,135 mm (44.7 in)
Seat Height:
Approx. 835 mm (32.9 in)
Wheelbase:
Approx. 1,405 mm (55.3 in)
Ground Clearance:
Approx. 135 mm (5.3 in)
Weights
Dry Weight:
Approx. 177 kg (390 lbs)
Wet Weight:
Approx. 205 kg (452 lbs) (fully fueled)
Fuel Capacity:
18 L (4.75 US gal)
🛡️ Safety Features
Ratings
Safety Ratings:
N/A (Motorcycle safety ratings differ from automotive, focus on design for rider safety)
Active Features
Braking System:
Dual 320mm front discs with radial-mount 4-piston calipers, 220mm rear disc with 2-piston caliper
Suspension Control:
Adjustable suspension for optimal handling and stability
Passive Features
Frame Design:
Rigid aluminum frame for predictable handling
Lighting:
Dual multi-reflector headlights for improved visibility
💡 Technology Features
Infotainment
Infotainment System:
N/A (Sportbike focused, no infotainment in the modern sense)
Driver Assistance
Rider Aids:
Assist and slipper clutch for smoother downshifts and reduced rear-wheel hop.
Electronics:
ECU controlled fuel injection and ignition timing for optimal performance across the rev range.
Connectivity
Connectivity Features:
N/A (No Bluetooth or smartphone integration on this model)
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 6,000 km (3,700 miles) or 6 months, whichever comes first (refer to manual for exact recommendation)
Air Filter Inspection:
Every 6,000 km (3,700 miles)
Spark Plug Replacement:
Every 18,000 km (11,000 miles)
Coolant Replacement:
Every 2 years or 24,000 km (15,000 miles)
Brake Fluid Replacement:
Every 2 years or 24,000 km (15,000 miles)
Fluid Specifications
Engine Oil Grade:
Yamalube 4 (or equivalent) 10W-40 API SG or higher
Coolant Type:
High-quality ethylene glycol based coolant, 50/50 mix with distilled water
Brake Fluid Type:
DOT 4
Fork Oil Type:
Yamaha Suspension Fluid 01 or SAE 5W (specific viscosity detailed in manual)
Known Issues
Common Wear Items:
Clutch plates, brake pads, chain and sprockets, tires
Potential Electrical:
Voltage regulator/rectifier failure (though less common on this generation than earlier models)
Engine Performance:
Can be sensitive to incorrect fuel or maintenance; proper valve clearance is crucial.
📚 Vehicle History
Brand Heritage
Brand Focus:
Yamaha has a long and successful history in motorcycle racing and performance road bikes.
Model Evolution
Yzf-R1 Lineage:
The R1 has been a benchmark in the liter-class sportbike segment since its 1998 debut. This generation (RN09) represented a significant evolution.
2004 Updates:
Introduced electronic fuel injection, revised chassis geometry, and improved suspension. The 'SC' designation often implied a special color scheme or minor specification enhancement.
2005 Updates:
Further refinement, often including minor styling tweaks or suspension adjustments.
2006 Updates:
Often considered the final year for this specific generation (RN09) before a more significant redesign.
Production
Manufacturing Location:
Japan
🏆 Awards & Recognition
Recognitions
Industry Recognition:
The YZF-R1 series has consistently received high praise from automotive journalists and riders for its performance and handling, often winning 'Bike of the Year' awards in its class.