YAMAHA YZF-R1SC 2004 Owners Manual

3-14
ADJUSTING THE VALVE CLEARANCE
CHK
ADJ
NOTE:
NOTE:
c. Round off the original valve pad number ac-
cording to the following table.
Last digit
Rounded value
0 or 20
55
810
EXAMPLE:
Original valve pad number
= 148 (thickness =1.48 mm (0.058 in))
Rounded value = 150
d. Locate the rounded number of the original
valve pad and the measured valve clearance
in the valve pad selection table. The point
where the column and row intersect is the
new valve pad number.
The new valve pad number is only an approxi-
mation. The valve clearance must be measured
again and the above steps should be repeated if
the measurement is still incorrect.
e. Install the new valve pad
1 and the valve lift-
er
2.

Lubricate the valve pad with molybdenum dis-
ulfide grease.

Lubricate the valve lifter with molybdenum dis-
ulfide oil.

The valve lifter must turn smoothly when ro-
tated by hand.

Install the valve lifter and the valve pad in the
correct place.
f. Install the exhaust and intake camshafts,
timing chain and camshaft caps.
Camshaft cap bolt
10 Nm (1.0 m
kg, 7.2 ft
lb)
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3-15
ADJUSTING THE VALVE CLEARANCE
CHK
ADJ
NOTE:

Refer to “ASSEMBLING AND ADJUSTING
THE ENGINE – CYLINDER HEAD AND CAM-
SHAFT” in chapter 5.

Lubricate the camshaft bearings, camshaft
lobes and camshaft journals.

First, install the exhaust camshaft.

Align the camshaft marks with the camshaft
cap marks.

Turn the crankshaft counterclockwise several
full turns to seat the parts.
g. Measure the valve clearance again.
h. If the valve clearance is still out of specifica-
tion, repeat all of the valve clearance adjust-
ment steps until the specified clearance is
obtained.
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3-16
ADJUSTING THE VALVE CLEARANCE
CHK
ADJ
VALVE CLEARANCE (cold):
0.11  0.20 mm (0.0043  0.0079 in)
Example: Installed is 175
Measured clearance is 0.27 mm (0.0106 in)
Replace 175 pad with 185 pad
Pad number: (example)
Pad No.175 = 1.75 mm (0.0689 in)
Pad No.185 = 1.85 mm (0.0728 in)
MEASURED
CLEARANCEINSTALLED PAD NUMBER
VALVE CLEARANCE (cold):
0.21  0.25 mm (0.0083  0.0098 in)
Example: Installed is 175
Measured clearance is 0.35 mm (0.0138 in)
Replace 175 pad with 185 pad
Pad number: (example)
Pad No.175 = 1.75 mm (0.0689 in)
Pad No.185 = 1.85 mm (0.0728 in)
MEASURED
CLEARANCEINSTALLED PAD NUMBER
STANDARD CLEARANCE
STANDARD CLEARANCE
INTAKE
120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.00  0.02 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225
0.03  0.07 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230
0.08  0.10 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235
0.11  0.20
0.21  0.25 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.26  0.30 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.31  0.35 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.36  0.40 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.41  0.45 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.46  0.50 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.51  0.55 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.56  0.60 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.61  0.65 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.66  0.70 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.71  0.75 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.76  0.80 180 185 190 195 200 205 210 215 220 225 230 235 240
0.81  0.85 185 190 195 200 205 210 215 220 225 230 235 240
0.86  0.90 190 195 200 205 210 215 220 225 230 235 240
0.91  0.95 195 200 205 210 215 220 225 230 235 240
0.96  1.00 200 205 210 215 220 225 230 235 240
1.01  1.05 205 210 215 220 225 230 235 240
1.06  1.10 210 215 220 225 230 235 240
1.11  1.15 215 220 225 230 235 240
1.16  1.20 220 225 230 235 240
1.21  1.25 225 230 235 240
1.26  1.30 230 235 240
1.31  1.35 235 240
1.36  1.40 240
EXHAUST
120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.00  0.02 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215
0.03  0.07 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220
0.08  0.12 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225
0.13  0.17 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230
0.18  0.20 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235
0.21  0.25
0.26  0.30 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.31  0.35 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.36  0.40 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.41  0.45 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.46  0.50 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.51  0.55 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.56  0.60 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.61  0.65 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.66  0.70 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.71  0.75 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.76  0.80 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.81  0.85 180 185 190 195 200 205 210 215 220 225 230 235 240
0.86  0.90 185 190 195 200 205 210 215 220 225 230 235 240
0.91  0.95 190 195 200 205 210 215 220 225 230 235 240
0.96  1.00 195 200 205 210 215 220 225 230 235 240
1.01  1.05 200 205 210 215 220 225 230 235 240
1.06  1.10 205 210 215 220 225 230 235 240
1.11  1.15 210 215 220 225 230 235 240
1.16  1.20 215 220 225 230 235 240
1.21  1.25 220 225 230 235 240
1.26  1.30 225 230 235 240
1.31  1.35 230 235 240
1.36  1.40 235 240
1.41  1.45 240
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3-17
ADJUSTING THE VALVE CLEARANCE /
SYNCHRONIZING THE THROTTLE BODIESCHK
ADJ
NOTE:
NOTE:
NOTE:
7. Install:

all removed parts
For installation, reverse the removal procedure.
SYNCHRONIZING THE THROTTLE BODIES
Prior to synchronizing the throttle bodies, the
valve clearance and the engine idling speed
should be properly adjusted and the ignition tim-
ing should be checked.
1. Stand the motorcycle on a level surface.
Place the motorcycle on a suitable stand.
2. Remove:

rider seat
Refer to “SEATS”.

fuel tank
Refer to “FUEL TANK”.
3. Remove:

synchronizing hoses
1
4. Install:

vacuum gauge
1
(onto the synchronizing hose)

digital tachometer
(near the spark plug)
Vacuum gauge
90890-03094, YU-08030
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3-18
SYNCHRONIZING THE THROTTLE BODIES
CHK
ADJ
NOTE:
CAUTION:
NOTE: 5. Install:

fuel tank
Refer to “FUEL TANK”.
6. Start the engine and let it warm up for several
minutes.
7. Measure:

engine idling speed
Out of specification
Adjust.
Refer to “ADJUSTING THE ENGINE IDLING
SPEED”.
Engine idling speed
1,150  1,250 r / min
8. Adjust:

throttle body synchronization
a. With throttle body #3 as standard, adjust
throttle bodies #1, #2, and #4 using the air
screws
1.

After each step, rev the engine two or three
times, each time for less than a second, and
check the synchronization again.

If the air screw is removed, turn the screw 3 / 4
turn in and be sure to synchronize the throttle
body.
Do not use the throttle valve adjusting
screws to adjust the throttle body synchro-
nization.
Vacuum pressure at engine
idling speed
22 kPa
(165 mmHg, 6.5 inHg)
The difference in vacuum pressure between
two throttle bodies should not exceed 1.33 kPa
(10 mmHg, 0.39 inHg).
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3-19
SYNCHRONIZING THE THROTTLE BODIES /
ADJUSTING THE EXHAUST GAS VOLUMECHK
ADJ
NOTE:
NOTE: 9. Measure:

engine idling speed
Out of specification
Adjust.
Make sure that the vacuum pressure is within
specification.
10. Stop the engine and remove the measuring
equipment.
11. Adjust:

throttle cable free play
Refer to “ADJUSTING THE THROTTLE
CABLE FREE PLAY”.
Throttle cable free play
(at the flange of the throttle grip)
3  5 mm (0.12  0.20 in)
13. Install:

synchronizing hoses

fuel tank
Refer to “FUEL TANK”.

rider seat
Refer to “SEATS”.
ADJUSTING THE EXHAUST GAS VOLUME
Be sure to set the carbon monoxide density to
standard, and then adjust the exhaust gas.
1. Turn the main switch to “OFF” and engine
stop switch “ON”.
2. While keeping the “SELECT” and “RESET”
buttons pressed simultaneously, turn “ON”
the main switch (keep them pressed for 8 se-
conds or more).
All indications on the meter disappear except
the clock and trip indications.
Letters “dIAG” appear on the clock LCD.
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3-20
ADJUSTING THE EXHAUST GAS VOLUME
CHK
ADJ
NOTE:
NOTE: 3. Using the “SELECT” button, select either the
Co adjustment mode
1 (which appears as
“Co”) or the diagnosis mode (which appears
as “dIAG”).
4. After “Co” appears as a result of pressing the
“SELECT” button, simultaneously press the
“SELECT” and “RESET” buttons for 2 se-
conds or more to excute the selection.
5. Press the “SELECT” and “RESET” buttons to
select the cylinder
2.

The adjustment cylinder appears on the clock
LCD.
“RESET” button = decrement
“SELECT” button = increment
6. Excute the selection of the cylinder by simul-
taneously pressing the “SELECT” and “RE-
SET” buttons for approximately 2 seconds.
7. After selecting the adjustment cylinder,
change the “Co” adjustment volume by
pressing the “SELECT” and “RESET” but-
tons.
The Co adjustment volume appears on the trip
LCD.
“RESET” button = decrement
“SELECT” button = increment
8. The selection is executed upon releasing the
finger from the switch.
9. Simultaneously press the “SELECT” and
“RESET” buttons to return to the cylinder
selection. (step 5)
10. Cancel the mode by turning “OFF” the main
switch.
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3-21
ADJUSTING THE ENGINE IDLING SPEED
CHK
ADJ
NOTE:
a
b
EAS00052
ADJUSTING THE ENGINE IDLING SPEED
Prior to adjusting the engine idling speed, the
throttle bodies synchronization should be ad-
justed properly, and the engine should have ad-
equate compression.
1. Start the engine and let it warm up for several
minutes.
2. Install:

digital tachometer
(near the spark plug)
3. Check:

engine idling speed
Out of specification
Adjust.
Engine idling speed
1,150  1,250 r / min
4. Adjust:

engine idling speed
a. Turn the idle adjusting screw
1 in direction
a or b until the specified engine idling
speed is obtained.
Direction
Engine idling speed is
increased.
DirectionEngine idling speed is
decreased.
5. Adjust:

throttle cable free play
Refer to “ADJUSTING THE THROTTLE
CABLE FREE PLAY”.
Throttle cable free play (at the
flange of the throttle grip)
3  5 mm (0.12  0.20 in)
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3-22
ADJUSTING THE THROTTLE CABLE FREE PLAY
CHK
ADJ
NOTE:
a
b
WARNING
EAS00056
ADJUSTING THE THROTTLE CABLE FREE
PLAY
Prior to adjusting the throttle cable free play, the
engine idling speed should be adjusted proper-
ly.
1. Check:

throttle cable free play
a
Out of specification
Adjust.
Throttle cable free play (at the
flange of the throttle grip)
3  5 mm (0.12  0.20 in)
2. Adjust:

throttle cable free play
Handlebar side
a. Loosen the locknut
1.
b. Turn the adjusting nut
2 in direction a or b
until the specified throttle cable free play is
obtained.
Direction
Throttle cable free play is
increased.
DirectionThrottle cable free play is
decreased.
c. Tighten the locknut.
After adjusting the throttle cable free play,
start the engine and turn the handlebars to
the right and to the left to ensure that this
does not cause the engine idling speed to
change.
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3-23
CHECKING THE SPARK PLUGS
CHK
ADJ
CAUTION:
EAS00059
CHECKING THE SPARK PLUGS
The following procedure applies to all of the
spark plugs.
1. Remove:

side cowlings

bottom cowlings
Refer to “COWLINGS”.
2. Remove:

radiator upper bolts

radiator lower bolt
Refer to “RADIATOR” in chapter 6.
3. Remove:

ignition coils

spark plugs
Before removing the spark plugs, blow away
any dirt accumulated in the spark plug wells
with compressed air to prevent it from fal-
ling into the cylinders.
4. Check:

spark plug type
Incorrect
Change.
Spark plug type (manufacturer)
CR9EK (NGK)
5. Check:

electrode
1
Damage / wear
Replace the spark plug.

insulator
2
Abnormal color
Replace the spark plug.
Normal color is medium-to-light tan.
6. Clean:

spark plug
(with a spark plug cleaner or wire brush)
7. Measure:

spark plug gap
a
(with a wire Thickness gauge)
Out of specification
Regap.
Spark plug gap
0.6  0.7 mm
(0.0236  0.0276 in)
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