checking oil YAMAHA YZF-R1SC 2004 Owner's Guide

5-68
OIL PAN AND OIL PUMPENG
EAS00367
CHECKING THE OIL DELIVERY PIPE AND
OIL PIPE
1. Check:

oil delivery pipe
1

oil pipe 2
Damage
Replace.
Obstruction
Wash and blow out with com-
pressed air.
EAS00368
CHECKING THE OIL STRAINER
1. Check:

oil strainer
1
Damage
Replace.
Contaminants
Clean with solvent.
EAS00373
CHECKING THE OIL NOZZLES
The following procedure applies to all of the oil
nozzles.
1. Check:

oil nozzle
1
Damage / wear
Replace the oil nozzle.

O-ring
2
Damage / wear
Replace.

oil nozzle passage
Obstruction
Blow out with compressed air.
EAS00374
ASSEMBLING THE OIL PUMP
1. Lubricate:

inner rotor

outer rotor

oil pump shaft
(with the recommended lubricant)
Recommended lubricant
Engine oil
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5-69
OIL PAN AND OIL PUMPENG
NOTE:
15 Nm (1.5 m
kg, 11 ft
lb)
NOTE:
12 Nm (1.2 m
kg, 8.7 ft
lb)
2. Install:

pin
1

inner rotor 2

outer rotor 3

oil pump housing 4
When installing the inner rotor, align the pin 1 in
the oil pump shaft with the groove
a in the inner
rotor
2.
3. Install:

oil / water pump driven sprocket
1
LOCTITE
5VY mark of the oil / water pump driven gear is
installed at oil pump side.
4. Check:

oil pump operation
Refer to “CHECKING THE OIL PUMP”.
INSTALLING THE OIL / WATER PUMP
ASSEMBLY
1. Install:

O-ring
New

oil / water pump assembly
1

dowel pin

bolts
2
LOCTITE
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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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5-81
CONNECTING RODS AND PISTONSENG
NOTE:
NOTE:
Piston ring side clearance
Top ring
0.030
0.065 mm
(0.0012
0.0026 in)
: 0.115 mm (0.0045 in)
2nd ring
0.020
0.055 mm
(0.0008
0.002 in)
: 0.115 mm (0.0045 in)
2. Install:

piston ring
(into the cylinder)
Level the piston ring into the cylinder with the
piston crown.
a5 mm (0.20 in)
3. Measure:

piston ring end gap
Out of specification
Replace the piston
ring.
The oil ring expander spacer’s end gap cannot
be measured. If the oil ring rail’s gap is exces-
sive, replace all three piston rings.
Piston ring end gap
Top ring
0.15
0.25 mm
(0.0059
0.0098 in)
: 0.50 mm (0.0197 in)
2nd ring
0.30
0.45 mm
(0.0118
0.0177 in)
: 0.80 mm (0.0315 in)
Oil ring
0.10
0.40 mm
(0.0039
0.0158 in)
CHECKING THE PISTON PINS
The following procedure applies to all of the pis-
ton pins.
1. Check:

piston pin
Blue discoloration / grooves
Replace the
piston pin and then check the lubrication sys-
tem.
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5-103
TRANSMISSIONENG
REMOVING THE TRANSMISSION
1. Remove:

drive axle assembly
1

shift drum retainers 2

shift fork guide bars

shift fork “L” and “R”

shift drum assembly

shift fork “C”
2. Remove:

bearing housing
1

main axle assembly 2
a. Insert two bolts 3 of the proper size, as
shown in the illustration, into the main axle
assembly bearing housing.
b. Tighten the bolts until they contact the crank-
case surface.
c. Continue tightening the bolts until the main
axle assembly comes free from the upper
crankcase.
3. Remove:

oil pipe
1

bearing 2
EAS00421
CHECKING THE SHIFT FORKS
The following procedure applies to all of the shift
forks.
1. Check:

shift fork cam follower
1

shift fork pawl 2
Bends / damage / scoring / wear
Replace
the shift fork.
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6-7
OIL COOLERCOOL
63 Nm (6.3 m
kg, 46 ft
lb)
NOTE:
EAS00458
CHECKING THE OIL COOLER
1. Check:

oil cooler
Cracks / damage
Replace.
2. Check:

oil cooler inlet hose

oil cooler outlet hose
Cracks / damage / wear
Replace.
EAS00459
INSTALLING THE OIL COOLER
1. Clean:

mating surfaces of the oil cooler and the
crankcase
(with a cloth dampened with lacquer thinner)
2. Install:

O-ring
New

oil cooler
1

washer 2 New

bolt
3

Before installing the oil cooler, lubricate the oil
cooler bolt and O-ring with a thin coat of engine
oil.

Make sure that the O-ring is positioned proper-
ly.

Align the projection
a on the oil cooler with the
slot
b in the crankcase.
3. Fill:

cooling system
(with the specified amount of the recom-
mended coolant)
Refer to “CHANGING THE COOLANT” in
chapter 3.

crankcase
(with the specified amount of the recom-
mended engine oil)
Refer to “CHANGING THE ENGINE OIL” in
chapter 3.
4. Check:

cooling system
Leaks
Repair or replace any faulty part.
5. Measure:

radiator cap opening pressure
Below the specified pressure
Replace the
radiator cap.
Refer to “CHECKING THE RADIATOR”.
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6-14
WATER PUMPCOOL
NOTE:
NOTE:
NOTE:
EAS00471
DISASSEMBLING THE WATER PUMP
1. Remove:

water pump seal
1
Tap out the water pump seal from the inside of
the water pump housing.
2Water pump housing
2. Remove:

oil seal
1

bearing 2
Tap out the bearing and oil seal from the outside
of the water pump housing.
3Water pump housing
3. Remove:

rubber damper holder
1

rubber damper 2
(from the impeller, with a thin, flat-head
screwdriver)
Do not scratch the impeller shaft.
EAS00473
CHECKING THE WATER PUMP
1. Check:

water pump housing cover
1

water pump housing 2

impeller 3

rubber damper 4

rubber damper holder 5

water pump seals

oil seal
Cracks / damage / wear
Replace.
2. Check:

bearing
Rough movement
Replace.
3. Check:

water pump outlet pipe
Cracks / damage / wear
Replace.
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8-4
11Neutral switch
12Rear brake light switch
13Fuse box
1Main switch
2Horn switch
3Dimmer switch
4Turn signal switch
5Clutch switch
6Sidestand switch
7Engine stop switch
8Front brake light switch
9Start switch
10Oil level switch
CHECKING THE SWITCHESELEC
EAS00731
CHECKING THE SWITCHES
Check each switch for damage or wear, proper connections, and also for continuity between the termi-
nals. Refer to “CHECKING SWITCH CONTINUITY”.
Damage / wear
Repair or replace.
Improperly connected
Properly connect.
Incorrect continuity reading
Replace the switch.
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8-6
CHECKING THE BULBS AND BULB SOCKETSELEC
CAUTION:
NOTE:

Be sure to hold the socket firmly when re-
moving the bulb. Never pull the lead, other-
wise it may be pulled out of the terminal in
the coupler.

Avoid touching the glass part of the head-
light bulb to keep it free from oil, otherwise
the transparency of the glass, the life of the
bulb, and the luminous flux will be adverse-
ly affected. If the headlight bulb gets soiled,
thoroughly clean it with a cloth moistened
with alcohol or lacquer thinner.
2. Check:

bulb (for continuity)
(with the pocket tester)
No continuity
Replace.
Pocket tester
90890-03112, YU-3112
Before checking for continuity, set the pocket
tester to “0” and to the “Ω
1” range.
a. Connect the positive tester probe to terminal
1 and the negative tester probe to terminal
2, and check the continuity.
b. Connect the positive tester probe to terminal
1 and the negative tester probe to terminal
3, and check the continuity.
c. If either of the readings indicate no continuity,
replace the bulb.
CHECKING THE CONDITION OF THE BULB
SOCKETS
The following procedure applies to all of the bulb
sockets.
1. Check:

bulb socket (for continuity)
(with the pocket tester)
No continuity
Replace.
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8-10
YESNO 2. Battery

Check the condition of the battery.
Refer to “CHECKING AND CHARGING
THE BATTERY” in chapter 3.
Minimum open-circuit voltage
12.8 V or more at 20C (68F)

Is the battery OK?

Clean the battery
terminals.

Recharge or re-
place the battery.
EAS00739
YESNO
EAS00741
3. Spark plugs
The following procedure applies to all of the
spark plugs.

Check the condition of the spark plug.

Check the spark plug type.

Measure the spark plug gap.
Refer to “CHECKING THE SPARK PLUGS”
in chapter 3.
Standard spark plug
CR9EK (NGK)
Spark plug gap
0.6  0.7 mm (0.0236  0.0276 in)

Is the spark plug in good condition, is it of the
correct type, and is its gap within specifica-
tion?
Re-gap or replace
the spark plug.
IGNITION SYSTEMELEC
NOTE:
YESNO
1. Main and ignition fuses

Check the main and ignition fuses for conti-
nuity.
Refer to “CHECKING THE FUSES” in chap-
ter 3.

Are the main and ignition fuses OK?
Replace the fuse(s).
EAS00737
TROUBLESHOOTING
The ignition system fails to operate (no
spark or intermittent spark).
Check:
1. main and ignition fuses
2. battery
3. spark plugs
4. ignition spark gap
5. ignition coil resistance
6. crankshaft position sensor
7. main switch
8. engine stop switch
9. neutral switch
10. sidestand switch
11. clutch switch
12. starting circuit cut-off relay (diode)
13. lean angle cut-off switch
14. wiring connections
(of the entire ignition system)

Before troubleshooting, remove the following
part(s):
1. seat
2. fuel tank
3. side cowlings

Troubleshoot with the following special tool(s).
Ignition checker
90890-06754
Dynamic spark tester
YM-34487
Pocket tester
90890-03112, YU-3112
EAS00738
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