spark plugs replace YAMAHA YZF-R1SC 2004 Service Manual

3-1
3
INTRODUCTION / PERIODIC MAINTENANCE CHART FOR THE EMISSION
CONTROL SYSTEM / GENERAL MAINTENANCE AND LUBRICATION CHARTCHK
ADJ
EAS00036
PERIODIC CHECKS AND ADJUSTMENTS
INTRODUCTION
This chapter includes all information necessary to perform recommended checks and adjustments. If
followed, these preventive maintenance procedures will ensure more reliable vehicle operation, a
longer service life and reduce the need for costly overhaul work. This information applies to vehicles
already in service as well as to new vehicles that are being prepared for sale, All service technicians
should be familiar with this entire chapter.
PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM
INITIALODOMETER READINGS
No.ITEMROUTINE600 mi
(1000 km)
or
1 month4000 mi
(7000 km)
or
6 months8000 mi
(13000 km)
or
12 months12000 mi
(19000 km)
or
18 months16000 mi
(25000 km)
or
24 months20000 mi
(31000 km)
or
30 months
1*Fuel line
(See page 3-33)
Check fuel hoses for cracks or damage.

Replace if necessary.





2*Spark plugs
(See page 3-23)
Check Condition.

Adjust gap and clean.

Replace every 8000 mi (13000 km) or 12
months.
Replace.
Replace.

3*Valve clearance
(See page 3-11)
Check and adjust valve clearance when en-
gine is cold.Every 26600 mi (42000 km)
4*Crankcase breather
system
(See page 3-34)
Check breather hose for cracks or damage.

Replace if necessary.





5*Electronic fuel injection
(See page 3-17, 21)
Check and adjust engine idle speed and syn-
chronization.






6*Exhaust system
(See page 3-35)
Check for leakage.

Tighten if necessary.

Replace gasket(s) if necessary.





7*Evaporative emission
control system
(For California only)
Check control system for damage.

Replace if necessary.


8*Air induction system
(See page 7-46)
Check the air cut-off valve, reed valve, and
hose for damage.

Replace any damaged parts if necessary.


GENERAL MAINTENANCE AND LUBRICATION CHART
INITIALODOMETER READINGS
No.ITEMROUTINE600 mi
(1000 km)
or
1 month4000 mi
(7000 km)
or
6 months8000 mi
(13000 km)
or
12 months12000 mi
(19000 km)
or
18 months16000 mi
(25000 km)
or
24 months20000 mi
(31000 km)
or
30 months
1*Air filter element
(See page 3-32)
Check condition and damage.
Replace if necessary.





2*Clutch
(See page 3-31)
Check operation.
Adjust or replace cable.






3*Front brake
(See page 3-42, 44, 45)
Check operation, fluid level, and for fluid leak-
age.

Replace brake pads if necessary.






4*Rear brake
(See page 3-43, 44, 45)
Check operation, fluid level, and for fluid leak-
age.

Replace brake pads if necessary.






5*Brake hoses
Check for cracks or damage.




5*Brake hoses(See page 3-46)
Replace.Every 4 years
6*Wheels
(See page 4-3)
Check runout and for damage.
Replace if necessary.





7*Tires
(See page 3-58)
Check tread depth and for damage.
Replace if necessary.
Check air pressure.
Correct if necessary.






8*Wheel bearings
(See page 4-3)
Check bearings for smooth operation.
Replace if necessary.





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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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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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8-11
IGNITION SYSTEMELEC
NOYES
1
a
2
4. Ignition spark gap
The following procedure applies to all of the
spark plugs.

Disconnect the spark plug cap from the
spark plug.

Connect the ignition checker and spark
plug cap as shown.

Set the main switch to “ON”.

Measure the ignition spark gap .

Crank the engine by pushing the starter
switch and gradually increase the spark gap
until a misfire occurs.
Minimum ignition spark gap
6 mm (0.24 in)

Is there a spark and is the spark gap within
specification?
The ignition system
is OK.
5. Ignition coil resistance
The following procedure applies to all of the
ignition coils.

Disconnect the ignition coil leads from the
wire harness.

Connect the pocket tester (Ω
1) to the
ignition coil as shown.
EAS00747
Positive tester probe

ignition coil terminal
Negative tester probe

ignition coil terminal

Connect the pocket tester (Ω
1k) to the
ignition coil as shown.
Measure the primary coil resistance.
Primary coil resistance
1.19  1.61 Ω at 20C
Negative tester probe

ignition coil terminal
Positive tester probe

spark plug terminal
1
2

Measure the secondary coil resistance.
Secondary coil resistance
8.5  11.5 kΩ at 20C

Is the ignition coil OK?
YESNO
Replace the ignition
coil.
EAS00743
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