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Yamaha Yzf-r1s Yzf-r1sc 2004 Workshop Service Repair Manual

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🏷️ Basic Information Identification Make: Yamaha Model: YZF-R1S / YZF-R1SC Year: 2004 Generation Model Generation: Second Generation (2004-2006) Codes Chassis Code: RN09 👋 Introduction Market Position Segment: High-performance Supersport Motorcycle Target Audience: Enthusiasts, DIY mechanics, and professional technicians working on Yamaha YZF-R1 models. Competitive Analysis Key Competitors: Honda CBR954RR Fireblade, Suzuki GSX-R1000 K4, Kawasaki ZX-10R Ninja, Ducati 999. Key Features Performance Focus: Emphasis on power, handling, and track-day capability. Engineering Philosophy: Yamaha's 'Kando' philosophy, aiming for emotional engagement and advanced technology. Manual Utility Value Proposition: Cost-effective alternative to dealership service, enabling owners to perform their own maintenance and repairs. 📋 Manual Details Coverage Areas Primary Coverage: Complete Service and Repair Included Variants: YZF-R1S, YZF-R1SC Page Count Estimated Page Count: 500+ Manual Type Type: Workshop Service Repair Manual Language Language: English Format Format: PDF Download File Format File Type: PDF Searchability: Typically searchable text, allowing for quick access to specific information. Print Quality Quality: High-resolution scans, ensuring clarity of text and diagrams. Binding Type Binding: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) 📖 Manual Coverage Systems Covered Engine: Comprehensive engine disassembly, assembly, diagnostics, and tuning for all components including crankshaft, pistons, valves, camshafts, and lubrication system. Fuel System: Detailed coverage of the fuel injection system (FI), throttle bodies, fuel pump, injectors, pressure regulator, and emissions control. Transmission: Complete service and repair for the 6-speed gearbox, clutch operation, gearbox internals, and shift mechanism. Chassis Suspension: In-depth procedures for front fork (USD) disassembly, service, adjustment, and rear shock absorber service and replacement. Includes swingarm and linkage maintenance. Brakes: Complete service for front and rear brake systems, including caliper overhaul, master cylinder service, brake line replacement, and bleeding procedures. Electrical System: Extensive coverage of wiring diagrams, component testing, ignition system, charging system (stator, regulator/rectifier), battery service, lighting, and starter system. Cooling System: Radiator, fan, coolant, thermostat, and water pump service and replacement procedures. Exhaust System: Information on exhaust manifold, catalytic converter (if applicable), and muffler service and replacement. Bodywork: Fairing removal and installation, seat, fuel tank, and minor body panel adjustments. Procedures Included Maintenance: Scheduled maintenance tasks, oil changes, filter replacements, spark plug servicing, chain adjustment, and brake pad inspection. Troubleshooting: Diagnostic flowcharts and step-by-step troubleshooting guides for common and intermittent issues across all major systems. Repair Rebuild: Detailed instructions for component disassembly, cleaning, inspection, repair, and reassembly for major mechanical and electrical parts. Diagnostics: Guidance on using diagnostic tools (if applicable) and interpreting error codes, along with manual diagnostic methods. Torque Specifications: Precise torque values for all critical fasteners and bolts throughout the motorcycle. Technical Depth Depth Level: Comprehensive (from routine maintenance to complete engine rebuilds and electrical system diagnostics). ⚙️ Engine Specifications Primary Engine Engine Type: Liquid-cooled, 4-stroke, DOHC, 5-valve per cylinder, inline-four Displacement: 998 cc Bore X Stroke: 74.0 mm x 58.0 mm Compression Ratio: 12.3:1 Performance Horsepower: Approx. 172 hp @ 11,000 rpm (claimed) Torque: Approx. 107 Nm (79 lb-ft) @ 9,000 rpm (claimed) Fuel System Fuel Delivery: Electronic Fuel Injection (Yamaha Fuel Injection - YFI) Throttle Control: Dual throttle valves per cylinder (YS YCC-T - Yamaha Chip Controlled Throttle) Ignition Ignition System: Digital TCI (Transistor Controlled Ignition) Lubrication Oil Type: Yamalube 4R or equivalent motorcycle-specific 10W-40 API SG, JASO MA 🔧 Transmission Standard Transmission Type: Constant mesh 6-speed Clutch Type: Wet, multiple disc, slipper clutch Features Gear Ratios: Refer to manual for specific ratios (e.g., 1st: 2.53, 2nd: 1.89, 3rd: 1.55, 4th: 1.33, 5th: 1.16, 6th: 1.00) Final Drive: O-ring sealed chain Fluid Specs Transmission Oil Type: Yamalube Hypoid Gear Oil SAE 80 or equivalent Fluid Capacity Transmission Oil Capacity: Approx. 0.85 L (0.89 US qt) 📐 Dimensions Exterior Length: 2,085 mm (82.1 in) Width: 705 mm (27.8 in) Height: 1,130 mm (44.5 in) Wheelbase: 1,405 mm (55.3 in) Ground Clearance: 135 mm (5.3 in) Weights Dry Weight: Approx. 177 kg (390 lbs) Wet Weight: Approx. 204 kg (450 lbs) Fuel Capacity: 18.0 L (4.8 US gal) Suspension Front Suspension: 43mm USD (Upright, Down-tube) telescopic fork, adjustable preload, compression, and rebound damping. Rear Suspension: Monoshock with adjustable preload, compression, and rebound damping. Link-type suspension. Wheels Tires Front Tire Size: 120/70ZR17 M/C (58W) Rear Tire Size: 190/50ZR17 M/C (73W) Front Wheel Type: 3.50 x 17 forged aluminum alloy Rear Wheel Type: 6.00 x 17 forged aluminum alloy 🛡️ Safety Features Ratings Safety Features: While dedicated crash ratings like cars are not applicable, design considerations prioritize rider protection and stability. Active Features Braking System: Radial-mount 4-piston calipers with dual 320mm discs (front), 220mm disc with 2-piston caliper (rear). Braided stainless steel lines. Lighting: Multi-reflector halogen headlights, LED tail light. Passive Features Frame Construction: Lightweight aluminum Deltabox frame with optimized rigidity balance. Ergonomics: Aggressive, forward-leaning riding posture designed for track performance and aerodynamic efficiency. 💡 Technology Features Infotainment Instrumentation: Digital tachometer, analog-style speedometer readout, gear position indicator, fuel gauge,...
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Yamaha Yzf-r1s Yzf-r1sc 2004 Workshop Service Repair Manual
🏷️ Basic Information
Identification
Make:
Yamaha
Model:
YZF-R1S / YZF-R1SC
Year:
2004
Generation
Model Generation:
Second Generation (2004-2006)
Codes
Chassis Code:
RN09
👋 Introduction
Market Position
Segment:
High-performance Supersport Motorcycle
Target Audience:
Enthusiasts, DIY mechanics, and professional technicians working on Yamaha YZF-R1 models.
Competitive Analysis
Key Competitors:
Honda CBR954RR Fireblade, Suzuki GSX-R1000 K4, Kawasaki ZX-10R Ninja, Ducati 999.
Key Features
Performance Focus:
Emphasis on power, handling, and track-day capability.
Engineering Philosophy:
Yamaha's 'Kando' philosophy, aiming for emotional engagement and advanced technology.
Manual Utility
Value Proposition:
Cost-effective alternative to dealership service, enabling owners to perform their own maintenance and repairs.
📋 Manual Details
Coverage Areas
Primary Coverage:
Complete Service and Repair
Included Variants:
YZF-R1S, YZF-R1SC
Page Count
Estimated Page Count:
500+
Manual Type
Type:
Workshop Service Repair Manual
Language
Language:
English
Format
Format:
PDF Download
File Format
File Type:
PDF
Searchability:
Typically searchable text, allowing for quick access to specific information.
Print Quality
Quality:
High-resolution scans, ensuring clarity of text and diagrams.
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Download)
📖 Manual Coverage
Systems Covered
Engine:
Comprehensive engine disassembly, assembly, diagnostics, and tuning for all components including crankshaft, pistons, valves, camshafts, and lubrication system.
Fuel System:
Detailed coverage of the fuel injection system (FI), throttle bodies, fuel pump, injectors, pressure regulator, and emissions control.
Transmission:
Complete service and repair for the 6-speed gearbox, clutch operation, gearbox internals, and shift mechanism.
Chassis Suspension:
In-depth procedures for front fork (USD) disassembly, service, adjustment, and rear shock absorber service and replacement. Includes swingarm and linkage maintenance.
Brakes:
Complete service for front and rear brake systems, including caliper overhaul, master cylinder service, brake line replacement, and bleeding procedures.
Electrical System:
Extensive coverage of wiring diagrams, component testing, ignition system, charging system (stator, regulator/rectifier), battery service, lighting, and starter system.
Cooling System:
Radiator, fan, coolant, thermostat, and water pump service and replacement procedures.
Exhaust System:
Information on exhaust manifold, catalytic converter (if applicable), and muffler service and replacement.
Bodywork:
Fairing removal and installation, seat, fuel tank, and minor body panel adjustments.
Procedures Included
Maintenance:
Scheduled maintenance tasks, oil changes, filter replacements, spark plug servicing, chain adjustment, and brake pad inspection.
Troubleshooting:
Diagnostic flowcharts and step-by-step troubleshooting guides for common and intermittent issues across all major systems.
Repair Rebuild:
Detailed instructions for component disassembly, cleaning, inspection, repair, and reassembly for major mechanical and electrical parts.
Diagnostics:
Guidance on using diagnostic tools (if applicable) and interpreting error codes, along with manual diagnostic methods.
Torque Specifications:
Precise torque values for all critical fasteners and bolts throughout the motorcycle.
Technical Depth
Depth Level:
Comprehensive (from routine maintenance to complete engine rebuilds and electrical system diagnostics).
⚙️ Engine Specifications
Primary Engine
Engine Type:
Liquid-cooled, 4-stroke, DOHC, 5-valve per cylinder, inline-four
Displacement:
998 cc
Bore X Stroke:
74.0 mm x 58.0 mm
Compression Ratio:
12.3:1
Performance
Horsepower:
Approx. 172 hp @ 11,000 rpm (claimed)
Torque:
Approx. 107 Nm (79 lb-ft) @ 9,000 rpm (claimed)
Fuel System
Fuel Delivery:
Electronic Fuel Injection (Yamaha Fuel Injection - YFI)
Throttle Control:
Dual throttle valves per cylinder (YS YCC-T - Yamaha Chip Controlled Throttle)
Ignition
Ignition System:
Digital TCI (Transistor Controlled Ignition)
Lubrication
Oil Type:
Yamalube 4R or equivalent motorcycle-specific 10W-40 API SG, JASO MA
🔧 Transmission
Standard
Transmission Type:
Constant mesh 6-speed
Clutch Type:
Wet, multiple disc, slipper clutch
Features
Gear Ratios:
Refer to manual for specific ratios (e.g., 1st: 2.53, 2nd: 1.89, 3rd: 1.55, 4th: 1.33, 5th: 1.16, 6th: 1.00)
Final Drive:
O-ring sealed chain
Fluid Specs
Transmission Oil Type:
Yamalube Hypoid Gear Oil SAE 80 or equivalent
Fluid Capacity
Transmission Oil Capacity:
Approx. 0.85 L (0.89 US qt)
📐 Dimensions
Exterior
Length:
2,085 mm (82.1 in)
Width:
705 mm (27.8 in)
Height:
1,130 mm (44.5 in)
Wheelbase:
1,405 mm (55.3 in)
Ground Clearance:
135 mm (5.3 in)
Weights
Dry Weight:
Approx. 177 kg (390 lbs)
Wet Weight:
Approx. 204 kg (450 lbs)
Fuel Capacity:
18.0 L (4.8 US gal)
Suspension
Front Suspension:
43mm USD (Upright, Down-tube) telescopic fork, adjustable preload, compression, and rebound damping.
Rear Suspension:
Monoshock with adjustable preload, compression, and rebound damping. Link-type suspension.
Wheels Tires
Front Tire Size:
120/70ZR17 M/C (58W)
Rear Tire Size:
190/50ZR17 M/C (73W)
Front Wheel Type:
3.50 x 17 forged aluminum alloy
Rear Wheel Type:
6.00 x 17 forged aluminum alloy
🛡️ Safety Features
Ratings
Safety Features:
While dedicated crash ratings like cars are not applicable, design considerations prioritize rider protection and stability.
Active Features
Braking System:
Radial-mount 4-piston calipers with dual 320mm discs (front), 220mm disc with 2-piston caliper (rear). Braided stainless steel lines.
Lighting:
Multi-reflector halogen headlights, LED tail light.
Passive Features
Frame Construction:
Lightweight aluminum Deltabox frame with optimized rigidity balance.
Ergonomics:
Aggressive, forward-leaning riding posture designed for track performance and aerodynamic efficiency.
💡 Technology Features
Infotainment
Instrumentation:
Digital tachometer, analog-style speedometer readout, gear position indicator, fuel gauge, clock, tripmeters, coolant temperature.
Driver Assistance
Ride Enhancements:
Slipper clutch for smoother downshifts and reduced rear-wheel hop under hard braking.
Connectivity
Diagnostic Port:
Likely includes a diagnostic connector for specialized tools, detailed in the manual for service.
🔧 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:
Inspect every 6,000 km (3,700 miles), clean/replace as needed. Refer to manual.
Spark Plug Replacement:
Replace every 12,000 km (7,500 miles). Refer to manual for specific plug type.
Valve Clearance Check:
Check every 18,000 km (11,000 miles). Refer to manual for precise procedure and clearances.
Fluid Specifications
Coolant Type:
Yamaha's recommended permanent type coolant (50% solution) or equivalent antifreeze.
Brake Fluid:
DOT 4 brake fluid.
Fork Oil:
Yamaha Fork Oil G10 or equivalent (refer to manual for specific type and viscosity).
Known Issues
Common Wear Items:
Clutch plates, brake pads, sprockets and chain, tires, fork seals due to high performance usage.
Potential Failures:
Regulator/rectifier failure (common on many sportbikes of this era), occasional issues with fuel pump or injectors if maintenance is neglected. Manual helps diagnose and repair.
📚 Vehicle History
Brand Heritage
Heritage Motorcycles:
Yamaha has a long and successful history in motorcycle racing and performance sports bikes, dating back to the 1950s. Known for innovation and engineering excellence.
Model Evolution
R1 Lineage:
The YZF-R1 has been Yamaha's flagship supersport since its introduction in 1998, consistently pushing the boundaries of performance and technology.
2004 Updates:
The 2004 model marked a significant redesign for the R1, featuring an all-new chassis, fuel injection, and styling. This generation (RN09) introduced the under-seat exhaust and more aggressive lines.
Production
Manufacturing Location:
Japan
Key Market Regions:
Global release, with significant presence in North America, Europe, and Asia.
🏆 Awards & Recognition
Recognitions
Motorcycle Press:
The R1 series consistently receives accolades from motorcycle publications for its performance, handling, and technological advancements.
Ratings
Performance Rankings:
Frequently ranked among the top supersport motorcycles of its time in comparitive tests.
Certifications
Emissions Compliance:
Designed to meet emissions standards for its model year in various global markets.
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