checking oil YAMAHA YZF-R1SC 2004 Owner's Manual

4-60
HANDLEBARSCHAS
NOTE:
WARNING
6. Install:

left handlebar switch
1
Align the projection a on the left handlebar
switch with the hole
b in the left handlebar.
7. Install:

handlebar grip
a. Apply a thin coat of rubber adhesive onto the
end of the left handlebar.
b. Slide the handlebar grip over the end of the
left handlebar.
c. Wipe off any excess rubber adhesive with a
clean rag.
Do not touch the handlebar grip until the
rubber adhesive has fully dried.
8. Adjust:

clutch cable free play
Refer to “ADJUSTING THE CLUTCH
CABLE FREE PLAY” in chapter 3.
Clutch cable free play
(at the end of the clutch lever)
10
15 mm (0.39
0.59 in)
9. Adjust:

throttle cable free play
Refer to “ADJUSTING THE THROTTLE
CABLE FREE PLAY” in chapter 3.
Throttle cable free play
(at the flange of the throttle grip)
3
5 mm (0.12
0.20 in)
CHECKING THE STEERING DAMPER
1. Check:

steering damper body
Damage / oil leaks
Replace.
(It replace with the assembly.)

steering damper rod
Bends / scratch
Replace.
(It replace with the assembly.)

bearing
Damage /pitting
Replace.
(It replace with the assembly.)
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4-68
REAR SHOCK ABSORBER ASSEMBLYCHAS
NOTE:
44 Nm (4.4 m
kg, 32 ft
lb)
44 Nm (4.4 m
kg, 32 ft
lb)
44 Nm (4.4 m
kg, 32 ft
lb)
EAS00695
CHECKING THE REAR SHOCK ABSORBER
ASSEMBLY
1. Check:

rear shock absorber rod
Bends / damage
Replace the rear shock
absorber assembly.

rear shock absorber
Gas leaks / oil leaks
Replace the rear
shock absorber assembly.

spring
Damage / wear
Replace the rear shock ab-
sorber assembly.

bushings
Damage / wear
Replace.

dust seals
Damage / wear
Replace.

bolts
Bends / damage / wear
Replace.
EAS00698
INSTALLING THE REAR SHOCK
ABSORBER ASSEMBLY
1. Lubricate:

spacers

bearings
Recommended lubricant
Lithium – soap-based grease
2. Install:

rear shock absorber assembly

When installing the rear shock absorber as-
sembly, lift up the swingarm.

Install the connecting arm front bolt from the
right.
3. Tighten:

rear shock absorber assembly upper nut

rear shock absorber assembly lower nut

relay arm-to swingarm nut
4. Install :

EXUP servo motor
Refer to “EXHAUST PIPE” in chapter 5.

bottom cowling
Refer to “COWLINGS” in chapter 3.
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4-73
SWINGARM AND DRIVE CHAINCHAS
NOTE: 3. Wash:

pivot shaft

dust covers

spacer

washers

bearings
Recommended cleaning solvent
Kerosene
4. Check:

dust covers
1

spacer 2
Damage / wear
Replace.

bearings
3
Damage / pitting
Replace.
5. Check:

connecting arms
1

relay arm 2
Damage / wear
Replace.
6. Check:

bearings
3

oil seals 4
Damage / pitting
Replace.
7. Check:

collars
5
Damage / scratches
Replace.
EAS00709
CHECKING THE DRIVE CHAIN
1. Measure:

ten-link section
a of the drive chain
Out of specification
Replace the drive
chain.
Ten-link drive chain section limit
(maximum)
150.1 mm (5.91 in)

While measuring the ten-link section, push
down on the drive chain to increase its tension.

Measure the length between drive chain roller
1 and 11 as shown.

Perform this measurement at two or three dif-
ferent places.
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5-31
VALVES AND VALVE SPRINGSENG
CAUTION:
NOTE:
a. Apply a coarse lapping compound a to the
valve face.
Do not let the lapping compound enter the
gap between the valve stem and the valve
guide.
b. Apply molybdenum disulfide oil onto the
valve stem.
c. Install the valve into the cylinder head.
d. Turn the valve until the valve face and valve
seat are evenly polished, then clean off all of
the lapping compound.
For the best lapping results, lightly tap the valve
seat while rotating the valve back and forth be-
tween your hands.
e. Apply a fine lapping compound to the valve
face and repeat the above steps.
f. After every lapping procedure, be sure to
clean off all of the lapping compound from
the valve face and valve seat.
g. Apply Mechanic’s blueing dye (Dykem) onto
the valve face.
h. Install the valve into the cylinder head.
i. Press the valve through the valve guide and
onto the valve seat to make a clear impres-
sion.
j. Measure the valve seat width
a again. If the
valve seat width is out of specification, reface
and lap the valve seat.
EAS00241
CHECKING THE VALVE SPRINGS
The following procedure applies to all of the
valve springs.
1. Measure:

valve spring free length
a
Out of specification
Replace the valve
spring.
Valve spring free length
Intake valve spring
39.3 mm (1.55 in)
: 37.3 mm (1.47 in)
Exhaust valve spring
39.3 mm (1.55 in)
: 37.3 mm (1.47 in)
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5-32
VALVES AND VALVE SPRINGSENG
2. Measure:

compressed valve spring force
a
Out of specification
Replace the valve
spring.
bInstalled length
Compressed valve spring force
(installed)
Intake valve spring
145.9
167.9 N
(14.88
17.12 kg,
32.80
37.74 lb) at
32.65 mm (1.285 in)
Exhaust valve spring
164.1
188.9 N
(16.73
19.26 kg,
36.89
42.46 lb) at
32.82 mm (12.92 in)
3. Measure:

valve spring tilt
a
Out of specification
Replace the valve
spring.
Spring tilt limit
Intake valve spring
1.7 mm (0.07 in)
Exhaust valve spring
1.7 mm (0.07 in)
EAS00242
CHECKING THE VALVE LIFTERS
The following procedure applies to all of the
valve lifters.
1. Check:

valve lifter
Damage / scratches
Replace the valve lift-
ers and cylinder head.
EAS00245
INSTALLING THE VALVES
The following procedure applies to all of the
valves and related components.
1. Deburr:

valve stem end
(with an oil stone)
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5-41
STARTER CLUTCH AND GENERATORENG
NOTE:
NOTE:
10 Nm (1.0 m
kg, 7.2 ft
lb)
INSTALLING THE STARTER CLUTCH
1. Install:

generator rotor
1

damper 2

driven gear 3

The hole side of the damper is installed to the
generator side.

Lubricate the engine oil
4.
2. Install:

starter clutch drive gear
1

collar 2

washer 3
Refer to “CHECKING THE STARTER
CLUTCH”.
3. Install:

washer
1

O-ring 2 New

spacer
3
Lubricate the engine oil to O-ring.
INSTALLING THE GENERATOR
1. Install:

idle gear shaft

idle gear
1

washer

idle gear shaft bolt
2
LOCTITE
2. Install:

generator rotor and starter clutch assembly
1
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5-54
CLUTCHENG
NOTE:
EAS00286
CHECKING THE PRESSURE PLATE
1. Check:

pressure plate
1
Cracks / damage
Replace.

bearing
2
Damage / wear
Replace.
EAS00287
CHECKING THE PULL LEVER SHAFT AND
PULL ROD
1. Check:

pull lever shaft pinion gear teeth
1

pull rod teeth 2
Damage / wear
Replace the pull rod and
pull lever shaft pinion gear as a set.
2. Check:

pull rod bearing
Damage / wear
Replace.
INSTALLING THE CLUTCH
1. Install:

clutch damper spring seat
1

clutch damper spring 2
2. Install:

friction plate 3
1

clutch plate 2 2
Lubricate the engine oil.
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5-61
SHIFT SHAFTENG
22 Nm (2.2 m
kg, 16 ft
lb)
NOTE: CHECKING THE SHIFT SHAFT
1. Check:

shift shaft
1
Bends / damage / wear
replace.

shift shaft spring
2

collar 3
Damage / wear
Replace.
CHECKING THE STOPPER LEVER
1. Check:

stopper lever
1
Bends / damage
Replace.
Roller turns roughly
Replace the stopper
lever.
INSTALLING THE SHIFT SHAFT
1. Install:

washer

stopper lever
1

stopper screw 2
LOCTITE

stopper lever spring 3
2. Install:

washer

collar

shift shaft spring
1

shift shaft 2

Mesh the stopper lever with the shift drum seg-
ment assembly.

Lubricate the oil seal lips with lithium soap
base grease.

Install the end of the shift shaft spring onto the
shift shaft spring stopper.
3. Install:

Washer
1

circlip 2 New
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5-66
OIL PAN AND OIL PUMPENG
NOTE:
EAS00362
REMOVING THE OIL PAN
1. Remove:

oil level switch
1

oil pan 2

oil pan gasket

dowel pins
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.
CHECKING THE SPROCKET AND CHAIN
1. Check:

oil / water pump assembly drive sprocket
1
Cracks / damage / wear
Replace the de-
fective part(-s).
2. Check:

oil / water pump assembly drive chain
1
Damage / stiffness
Replace the oil / water
pump assembly drive chain and oil / water
pump assembly drive sprocket as a set.
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5-67
OIL PAN AND OIL PUMPENG
EAS00364
CHECKING THE OIL PUMP
1. Check:

oil pump driven gear
1

oil pump rotor housing 2

oil pump cover
Cracks / damage / wear
Replace the de-
fective part(s).
2. Measure:

inner-rotor-to-outer-rotor-tip clearance
a

outer-rotor-to-oil-pump-housing clearance
b
1Inner rotor
2Outer rotor
3Oil pump housing
Inner-rotor-to-outer-rotor-tip
clearance
0.01
0.10 mm
(0.0004
0.0039 in)
: 0.18 mm (0.0071 in)
Outer-rotor-to-oil-pump-housing
clearance
0.09
0.15 mm
(0.0035
0.0059 in)
: 0.22 mm (0.0087 in)
3. Check:

oil pump operation
Rough movement
Repeat steps (1) and
(2) or replace the defective part(s).
EAS00365
CHECKING THE RELIEF VALVE
1. Check:

relief valve body
1

relief valve 2

spring 3

O-ring 4
Damage / wear
Replace the defective
part(s).
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