seats YAMAHA YZF-R1SC 2004 Owner's Manual

5-23
CYLINDER HEADENG
NOTE:
NOTE:
NOTE:
EAS00222
REMOVING THE CYLINDER HEAD
1. Remove:

intake camshaft

exhaust camshaft
Refer to “REMOVING THE CAMSHAFTS”.
2. Remove:

cylinder head nuts

cylinder head bolts

Loosen the nuts in the proper sequence as
shown.

Loosen each nut 1 / 2 of a turn at a time. After all
of the nuts are fully loosened, remove them.
EAS00227
CHECKING THE CYLINDER HEAD
1. Eliminate:

combustion chamber carbon deposits
(with a rounded scraper)
Do not use a sharp instrument to avoid damag-
ing or scratching:

spark plug bore threads

valve seats
2. Check:

cylinder head
Damage / scratches
Replace.
3. Measure:

cylinder head warpage
Out of specification
Resurface the cylin-
der head.
Maximum cylinder head warpage
0.10 mm (0.0039 in)
a. Place a straightedge
1 and a thickness
gauge
2 across the cylinder head.
b. Measure the warpage.
c. If the limit is exceeded, resurface the cylinder
head as follows.
d. Place a 400
600 grit wet sandpaper on the
surface plate and resurface the cylinder
head using a figure-eight sanding pattern.
To ensure an even surface, rotate the cylinder
head several times.
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5-27
VALVES AND VALVE SPRINGSENG
NOTE:
NOTE:
NOTE:
NOTE:
EAS00237
REMOVING THE VALVES
The following procedure applies to all of the
valves and related components.
Before removing the internal parts of the cylin-
der head (e.g., valves, valve springs, valve
seats), make sure the valves properly seal.
1. Remove:

valve lifter
1

valve pad 2
Make a note of the position of each valve lifter
and valve pad so that they can be reinstalled in
their original place.
2. Check:

valve sealing
Leakage at the valve seat
Check the valve
face, valve seat, and valve seat width.
Refer to “CHECKING THE VALVE SEATS”.
a. Pour a clean solvent
a into the intake and
exhaust ports.
b. Check that the valves properly seal.
There should be no leakage at the valve seat
1.
3. Remove:

valve cotters
1
Remove the valve cotters by compressing the
valve spring with the valve spring compressor
2 and the valve spring compressor attachment
3.
Valve spring compressor
90890-04019, YM-04019
Valve spring compressor
attachment
Intake valve
90890-04114, YM-4114
Exhaust valve
90890-04108, YM-4108
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5-30
VALVES AND VALVE SPRINGSENG
NOTE:
NOTE:
EAS00240
CHECKING THE VALVE SEATS
The following procedure applies to all of the
valves and valve seats.
1. Eliminate:

carbon deposits
(from the valve face and valve seat)
2. Check:

valve seat
Pitting / wear
Replace the cylinder head.
3. Measure:

valve seat width
a
Out of specification
Replace the cylinder
head.
Valve seat width
Intake: 0.9
1.1 mm
Intake: (0.0354
0.0433 in)
Exhaust: 0.9
1.1 mm
Exhaust: (0.0354
0.0433 in)
: 1.6 mm (0.06 in)
a. Apply Mechanic’s blueing dye (Dykem)
1
onto the valve face.
b. Install the valve into the cylinder head.
c. Press the valve through the valve guide and
onto the valve seat to make a clear impres-
sion.
d. Measure the valve seat width.
Where the valve seat and valve face contacted
one another, the blueing will have been re-
moved.
4. Lap:

valve face

valve seat
After replacing the cylinder head or replacing
the valve and valve guide, the valve seat and
valve face should be lapped.
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5-35
Order Job / Part Q’ty Remarks
1
2
3
4
5
6
7
8
9Removing the stator coil assembly
Rider seat
Fuel tank
Left side cowling
Bottom cowlings
Engine oil
Stator coil assembly lead coupler
Plug
Generator rotor cover
Gasket
Dowel pin
Generator rotor assembly
Dowel pin
Bearing housing
Collar1
1
1
1
2
1
2
1
1Remove the parts in the order listed.
Refer to “SEATS” in chapter 3.
Refer to “FUEL TANK” in chapter 3.
Refer to “COWLINGS” in chapter 3.
Drain.
Refer to “CHANGING THE ENGINE OIL”
in chapter 3.
Disconnect.
10 Nm (1.0 m
kg, 7.2 ft
lb)
12 Nm (1.2 m
kg, 8.7 ft
lb)
12 Nm (1.2 m
kg, 8.7 ft
lb)
12 Nm (1.2 m
kg, 8.7 ft
lb)
10 Nm (1.0 m
kg, 7.2 ft
lb)
10 Nm (1.0 m
kg, 7.2 ft
lb)
14 Nm (1.4 m
kg, 10 ft
lb)
22 Nm (2.2 m
kg, 16 ft
lb)
22 Nm (2.2 m
kg, 16 ft
lb)
STARTER CLUTCH AND GENERATORENG
STARTER CLUTCH AND GENERATOR
STATOR COIL ASSEMBLY
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5-38
STARTER CLUTCH AND GENERATORENG
NOTE: REMOVING THE GENERATOR
1. Remove:

rider seat

fuel tank
Refer to “SEATS” and “FUEL TANK” in chapter
3.
2. Remove:

left side cowling

bottom cowlings
Refer to “COWLINGS” in chapter 3.
3. Drain:

engine oil
Refer to “CHANGING THE ENGINE OIL” in
chapter 3.
4. Remove:

plug

generator rotor cover
1

While pushing generator rotor, remove the
generator rotor cover.

Loosen each bolt 1 / 4 of a turn a time, in stages
and in a crisscross pattern.

After all of the bolts are fully loosened, remove
them.
5. Remove:

generator rotor and starter clutch assembly
1.
6. Remove:

idler gear shaft bolt
1

idler shaft

idler gear
2
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5-42
STARTER CLUTCH AND GENERATORENG
12 Nm (1.2 m
kg, 8.7 ft
lb)
22 Nm (2.2 m
kg, 16 ft
lb)
NOTE: 3. Install:

generator cover gasket

generator cover
1
(M6 bolts)
(M8 bolts)

First tighten the M8 bolts and then tighten the
M6 bolts.

Tighten the generator rotor cover bolts in
stages and in a crisscross pattern.
4. Fill:

engine oil
Refer to “CHANGING THE ENGINE OIL” in
chapter 3.
5. Install:

bottom cowling

left side cowling
Refer to “COWLINGS” in chapter 3.
6. Install:

fuel tank

rider seat
Refer to “SEATS” and “FUEL TANK” in chap-
ter 3.
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5-43
Order Job / Part Q’ty Remarks
1
2
3
4
5
6Removing the crankshaft position
sensor
Rider seat
Fuel tank
Side cowlings
Bottom cowlings
Engine oil
Crankshaft position sensor lead coupler
Crankshaft position sensor
O-ring
Pickup rotor cover
Gasket
Cover1
1
1
1
1
1Remove the parts in the order listed.
Refer to “SEATS” in chapter 3.
Refer to “FUEL TANK” in chapter 3.
Refer to “COWLINGS” in chapter 3.
Drain.
Refer to “CHANGING THE ENGINE OIL”
in chapter 3.
Disconnect.
For installation, reverse the removal
procedure.
10 Nm (1.0 m
kg, 7.2 ft
lb)
12 Nm (1.2 m
kg, 8.7 ft
lb)
12 Nm (1.2 m
kg, 8.7 ft
lb)
12 Nm (1.2 m
kg, 8.7 ft
lb)
CRANKSHAFT POSITION SENSORENG
CRANKSHAFT POSITION SENSOR
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5-44
CRANKSHAFT POSITION SENSORENG
NOTE:
12 Nm (1.2 m
kg, 8.7 ft
lb)
10 Nm (1.0 m
kg, 7.2 ft
lb)
REMOVING THE CRANKSHAFT POSITION
SENSOR
1. Remove:

rider seat

fuel tank
Refer to “SEATS” and “FUEL TANK” in chap-
ter 3.
2. Remove:

right side cowling

bottom cowlings
Refer to “COWLINGS” in chapter 3.
3. Drain:

engine oil
Refer to “CHANGING THE ENGINE OIL” in
chapter 3.
4. Disconnect:

crankshaft position sensor lead coupler
5. Remove:

crankshaft position sensor

O-ring

pickup rotor cover
1
Loosen each bolt 1 / 4 of a turn a time, in stages
and in a crisscross pattern.
After all of the bolts are fully loosened, remove
them.
INSTALLING THE CRANKSHAFT POSITION
SENSOR
1. Install:

gasket
New

pickup rotor cover
1

O-ring New

crankshaft position sensor
LOCTITE
2. Connect:

crankshaft position sensor lead coupler
3. Fill:

engine oil
Refer to “CHANGING THE ENGINE OIL” in
chapter 3.
4. Install:

right side cowling

bottom cowlings
Refer to “COWLINGS” in chapter 3.
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5-45
CRANKSHAFT POSITION SENSORENG
5. Install:

rider seat

fuel tank
Refer to “SEATS” and “FUEL TANK” in chap-
ter 3.
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6-1
Order Job / Part Q’ty Remarks
1
2
3
4
5Removing the radiator
Rider seat
Fuel tank
Air filter case
Side cowlings
Bottom cowling
Coolant
Fuse box stay
Coolant reservoir hose
Radiator
Radiator fan motor
Radiator inlet hose1
1
1
2
1Remove the parts in the order listed.
Refer to “AIR FILTER CASE” in chapter 3.
Drain.
Refer to “CHANGING THE COOLANT” in
chapter 3.
Disconnect.
Refer to “COWLINGS” in chapter 3.
Refer to “SEATS” in chapter 3.
10 Nm (1.0 m
kg, 7.2 ft
lb)
10 Nm (1.0 m
kg, 7.2 ft
lb)
5 Nm (0.5 m
kg, 3.6 ft
lb)
10 Nm (1.0 m
kg, 7.2 ft
lb)
RADIATORCOOL
EAS00454
COOLING SYSTEM
RADIATOR
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