engine YAMAHA YZF-R1SC 2004 Owners Manual

5-71
OIL PAN AND OIL PUMPENG
12 Nm (1.2 m
kg, 8.7 ft
lb)
10 Nm (1.0 m
kg, 7.2 ft
lb)
43Nm (4.3 m
kg, 31 ft
lb)
WARNING
NOTE:
EAS00380
INSTALLING THE OIL PAN
1. Install:

dowel pins

gasket
New

oil pan
1

oil level switch 2

engine oil drain bolt 3
Always use new copper washers.

Tighten the oil pan bolts in stages and in a
crisscross pattern.

Lubricate the oil level switch O-ring with en-
gine oil.
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5-72
Order Job / Part Q’ty Remarks
Removing the crankcase
Air filter case
Throttle body assembly
Engine
Cylinder head
Starter clutch and generator
Shift shaft
Crankshaft position sensor
Clutch
Oil pan and oil pump
Starter motorRemove the parts in the order listed.
Refer to “AIR FILTER CASE” in chapter 3.
Refer to “THROTTLE BODIES” in
chapter 7.
Refer to “ENGINE”.
Refer to “CYLINDER HEAD”.
Refer to “STARTER CLUTCH AND
GENERATOR”.
Refer to “SHIFT SHAFT”.
Refer to “CRANKSHAFT POSITION
SENSOR”.
Refer to “CLUTCH”.
Refer to “OIL PAN AND OIL PUMP”.
Refer to “STARTING SYSTEM” in
chapter 8.
12 Nm (1.2 m
kg, 8.7 ft
lb)12 Nm (1.2 m
kg, 8.7 ft
lb)
24 Nm (2.4 m
kg, 17 ft
lb)
10 Nm (1.0 m
kg, 7.2 ft
lb)
24 Nm (2.4 m
kg, 17 ft
lb)
12 Nm (1.2 m
kg, 8.7 ft
lb)
20 Nm (2.0 m
kg, 14 ft
lb) +60
CRANKCASEENG
CRANKCASE
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5-74
CRANKCASEENG
NOTE:
CAUTION:
NOTE:
EAS00384
DISASSEMBLING THE CRANKCASE
1. Place the engine upside down.
2. Remove:

crankcase bolts

Loosen each bolt 1 / 4 of a turn at a time, in
stages and in a crisscross pattern. After all of
the bolts are fully loosened, remove them.

Loosen the bolts in decreasing numerical or-
der (refer to the numbers in the illustration).

The numbers embossed on the crankcase in-
dicate the crankcase tightening sequence.
M9  105 mm (4.1 in) bolts:
1
10
M8  60 mm (2.4 in) bolt: 11 LOCTITE
M8  60 mm (2.4 in) bolts: 12, 16
M6  70 mm (2.8 in) bolts: 19, 21, 23
M6  65 mm (2.5 in) bolts: 17, 18
M6  60 mm (2.4 in) bolts: 22, 24, 25
M6  50 mm (2.0 in) bolts: 20, 26
M8  50 mm (2.0 in) bolts: 13
15
3. Remove:

lower crankcase
Tap on one side of the crankcase with a soft-
face hammer. Tap only on reinforced por-
tions of the crankcase, not on the crankcase
mating surfaces. Work slowly and carefully
and make sure the crankcase halves sepa-
rate evenly.
4. Remove:

dowel pins
5. Remove:

crankshaft journal lower bearing
(from the lower crankcase)
Identify the position of each crankshaft journal
lower bearing so that it can be reinstalled in its
original place.
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5-75
CRANKCASEENG
NOTE:
EAS00399
CHECKING THE CRANKCASE
1. Thoroughly wash the crankcase halves in a
mild solvent.
2. Thoroughly clean all the gasket surfaces and
crankcase mating surfaces.
3. Check:

crankcase
Cracks / damage
Replace.

oil delivery passages
Obstruction
Blow out with compressed air.
EAS00401
CHECKING THE BEARINGS AND OIL
SEALS
1. Check:

bearings
Clean and lubricate the bearings, then rotate
the inner race with your finger.
Rough movement
Replace.
2. Check:

oil seals
Damage / wear
Replace.
ASSEMBLING THE CRANKCASE
1. Lubricate:

crankshaft journal bearings
(with the recommended lubricant)
Recommended lubricant
Engine oil
2. Apply:

sealant
Yamaha bond No. 1215
90890-85505, ACC-1109-05-01
Do not allow any sealant to come into contact
with the oil gallery or crankshaft journal bear-
ings. Do not apply sealant to within 2
3 mm
(0.08
0.12 in) of the crankshaft journal bear-
ings.
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5-76
CRANKCASEENG
CAUTION:
NOTE:
3. Install:

dowel pin
4. Set the shift drum assembly and transmis-
sion gears in the neutral position.
5. Install:

lower crankcase
1
(onto the upper crankcase 2)
Before tightening the crankcase bolts, make
sure that the transmission gears shift cor-
rectly when the shift drum assembly is
turned by hand.
6. Install:

crankcase bolts

Lubricate the bolt threads with engine oil.

Install a washer on bolts
1
10 and 22.

Seal bolt
18

Tighten the bolts in the tightening sequence
cast on the crankcase.
M9  105 mm (4.1 in) bolts:
1
10
M8  60 mm (2.4 in) bolt: 11 LOCTITE
M8  60 mm (2.4 in) bolts: 12, 16
M6  70 mm (2.8 in) bolts: 19, 21, 23
M6  65 mm (2.5 in) bolts: 17, 18
M6  60 mm (2.4 in) bolts: 22, 24, 25
M6  50 mm (2.0 in) bolts: 20, 26
M8  50 mm (2.0 in) bolts: 13
15
Crankcase bolt
Bolt
1
10
1st: 20 Nm (2.0 m
kg, 14 ft
lb)
2nd*: 20 Nm (2.0 m
kg, 14 ft
lb)
3rd: +60
Bolt
11
16
24 Nm (2.4 m
kg, 17 ft
lb)
Bolt
17
26
12 Nm (1.2 m
kg, 8.7 ft
lb)
* Following the tightening order, loosen the bolt
one by one and then retighten it to the specific
torque.
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5-83
CAUTION:
CONNECTING RODS AND PISTONSENG
NOTE:
NOTE:
Do not interchange the big end bearings and
connecting rods. To obtain the correct
crankshaft-pin-to-big-end-bearing clear-
ance and prevent engine damage, the big
end bearings must be installed in their origi-
nal positions.
a. Clean the big end bearings, crankshaft pins,
and the inside of the connecting rods halves.
b. Install the big end upper bearing into the con-
necting rod and the big end lower bearing
into the connecting rod cap.
Align the projections
a on the big end bearings
with the notches
b in the connecting rod and
connecting rod cap.
c. Put a piece of Plastigauge
 1 on the crank-
shaft pin.
d. Assemble the connecting rod halves.

Do not move the connecting rod or crankshaft
until the clearance measurement has been
completed.

Lubricate the bolt threads with molybdenum
disulfide grease.

Make sure that the “Y” mark
c on the connect-
ing rod faces towards the left side of the crank-
shaft.

Make sure that the characters
d on both the
connecting rod and connecting rod cap are
aligned.
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5-87
CONNECTING RODS AND PISTONSENG
NOTE:
NOTE:
Be sure to install the piston rings so that the
manufacturer’s marks or numbers
a face up.
2. Install:

piston
1
(onto the respective connecting rod 2)

piston pin
3

piston pin clip New 4

Apply engine oil onto the piston pin.

Make sure that the “Y” mark
a on the connect-
ing rod faces left when the arrow mark
b on
the piston is pointing up. Refer to the illustra-
tion.

Reinstall each piston into its original cylinder
(numbering order starting from the left: #1 to
#4).
3. Lubricate:

piston

piston rings

cylinder
(with the recommended lubricant)
Recommended lubricant
Engine oil
4. Offset:

piston ring end gaps
aTop ring
bLower oil ring rail
cUpper oil ring rail
d2nd ring
eOil ring expander
5. Lubricate:

crankshaft pins

big end bearings

connecting rod big end inner surface
(with the recommended lubricant)
Recommended lubricant
Engine oil
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5-93
CRANKSHAFTENG
CAUTION:
EAS00395
CHECKING THE CRANKSHAFT
1. Measure:

crankshaft runout
Out of specification
Replace the crank-
shaft.
Crankshaft runout
Less than 0.03 mm (0.0012 in)
2. Check:

crankshaft journal surfaces

crankshaft pin surfaces

bearing surfaces
Scratches / wear
Replace the crankshaft.
CHECKING THE CRANKSHAFT DRIVE
SPROCKET
1. Check:

crankshaft drive sprocket
1
Cracks / damage / wear
Replace the de-
fective part(s).
CHECKING THE CRANKSHAFT JOURNAL
BEARINGS
1. Measure:

crankshaft-journal-to-crankshaft-journal-
bearing clearance
Out of specification
Replace the crank-
shaft journal bearings.
Crankshaft-journal-to-crankshaft-
journal-bearing clearance
0.014
0.037 mm
(0.0006
0.0015 in)
<Limit>: 0.10 mm (0.0039 in)
Do not interchange the crankshaft journal
bearings. To obtain the correct crankshaft-
journal-to-crankshaft-journal-bearing clear-
ance and prevent engine damage, the crank-
shaft journal bearings must be installed in
their original positions.
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5-96
CRANKSHAFTENG
NOTE:
60 Nm (6.0 m
kg, 43 ft
lb)
EAS00407
INSTALLING THE CRANKSHAFT
1. Install:

crankshaft journal upper bearings
1
(into the upper crankcase)
2. Lubricate:

crankshaft journal upper bearings
(with the recommended lubricant)
Recommended lubricant
Engine oil

Align the projections
a on the crankshaft jour-
nal upper bearings with the notches
b in the
upper crankcase.

Be sure to install each crankshaft journal up-
per bearing in its original place.
3. Install:

crankshaft
4. Install:

crankcase (lower)
Refer to “CRANKCASE”.
5. Install:

pin

pickup rotor
1

drive sprocket 2
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5-105
TRANSMISSIONENG
NOTE:
12 Nm (1.2 m
kg, 8.7 ft
lb)
10 Nm (1.0 m
kg, 7.2 ft
lb)
NOTE: 2. Measure:

drive axle runout
(with a centering device and dial gauge
1)
Out of specification
Replace the drive
axle.
Drive axle runout limit
0.08 mm (0.0032 in)
3. Check:

transmission gears
Blue discoloration / pitting / wear
Replace
the defective gear(s).

transmission gear dogs
Cracks / damage / rounded edges
Replace
the defective gear(s).
INSTALLING THE TRANSMISSION
1. Install:

bearing
1
Make the seal side of bearing face to the outside
and install it close to the right end face of the
crankcase.

oil pipe
2
2. Install:

main axle assembly
1

bearing housing 2
LOCTITE

shift fork “C”

shift drum assembly

shift fork guide bar

shift fork guide bar retainer
LOCTITE

The embossed marks on the shift forks should
face towards the right side of the engine and
be in the following sequence: “R”, “C”, “L”.

Carefully position the shift forks so that they
are installed correctly into the transmission
gears.

Install shift fork “C” into the groove in the 3rd
and 4th pinion gear on the main axle.
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