2004 YAMAHA YZF-R1SC engine

5-87
CONNECTING RODS AND PISTONSENG
NOTE:
NOTE:
Be sure to install the piston rings so that the
manufacturer’s marks or numbers
a face up.
2. Install:

piston
1
(onto the respective connecting rod 2)

piston pin
3

piston pin clip New 4

Apply engine oil onto the piston pin.

Make sure that the “Y” mark
a on the connect-
ing rod faces left when the arrow mark
b on
the piston is pointing up. Refer to the illustra-
tion.

Reinstall each piston into its original cylinder
(numbering order starting from the left: #1 to
#4).
3. Lubricate:

piston

piston rings

cylinder
(with the recommended lubricant)
Recommended lubricant
Engine oil
4. Offset:

piston ring end gaps
aTop ring
bLower oil ring rail
cUpper oil ring rail
d2nd ring
eOil ring expander
5. Lubricate:

crankshaft pins

big end bearings

connecting rod big end inner surface
(with the recommended lubricant)
Recommended lubricant
Engine oil
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5-93
CRANKSHAFTENG
CAUTION:
EAS00395
CHECKING THE CRANKSHAFT
1. Measure:

crankshaft runout
Out of specification
Replace the crank-
shaft.
Crankshaft runout
Less than 0.03 mm (0.0012 in)
2. Check:

crankshaft journal surfaces

crankshaft pin surfaces

bearing surfaces
Scratches / wear
Replace the crankshaft.
CHECKING THE CRANKSHAFT DRIVE
SPROCKET
1. Check:

crankshaft drive sprocket
1
Cracks / damage / wear
Replace the de-
fective part(s).
CHECKING THE CRANKSHAFT JOURNAL
BEARINGS
1. Measure:

crankshaft-journal-to-crankshaft-journal-
bearing clearance
Out of specification
Replace the crank-
shaft journal bearings.
Crankshaft-journal-to-crankshaft-
journal-bearing clearance
0.014
0.037 mm
(0.0006
0.0015 in)
: 0.10 mm (0.0039 in)
Do not interchange the crankshaft journal
bearings. To obtain the correct crankshaft-
journal-to-crankshaft-journal-bearing clear-
ance and prevent engine damage, the crank-
shaft journal bearings must be installed in
their original positions.
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5-96
CRANKSHAFTENG
NOTE:
60 Nm (6.0 m
kg, 43 ft
lb)
EAS00407
INSTALLING THE CRANKSHAFT
1. Install:

crankshaft journal upper bearings
1
(into the upper crankcase)
2. Lubricate:

crankshaft journal upper bearings
(with the recommended lubricant)
Recommended lubricant
Engine oil

Align the projections
a on the crankshaft jour-
nal upper bearings with the notches
b in the
upper crankcase.

Be sure to install each crankshaft journal up-
per bearing in its original place.
3. Install:

crankshaft
4. Install:

crankcase (lower)
Refer to “CRANKCASE”.
5. Install:

pin

pickup rotor
1

drive sprocket 2
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5-105
TRANSMISSIONENG
NOTE:
12 Nm (1.2 m
kg, 8.7 ft
lb)
10 Nm (1.0 m
kg, 7.2 ft
lb)
NOTE: 2. Measure:

drive axle runout
(with a centering device and dial gauge
1)
Out of specification
Replace the drive
axle.
Drive axle runout limit
0.08 mm (0.0032 in)
3. Check:

transmission gears
Blue discoloration / pitting / wear
Replace
the defective gear(s).

transmission gear dogs
Cracks / damage / rounded edges
Replace
the defective gear(s).
INSTALLING THE TRANSMISSION
1. Install:

bearing
1
Make the seal side of bearing face to the outside
and install it close to the right end face of the
crankcase.

oil pipe
2
2. Install:

main axle assembly
1

bearing housing 2
LOCTITE

shift fork “C”

shift drum assembly

shift fork guide bar

shift fork guide bar retainer
LOCTITE

The embossed marks on the shift forks should
face towards the right side of the engine and
be in the following sequence: “R”, “C”, “L”.

Carefully position the shift forks so that they
are installed correctly into the transmission
gears.

Install shift fork “C” into the groove in the 3rd
and 4th pinion gear on the main axle.
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6-5
Order Job / Part Q’ty Remarks
1
2
3
4
5
6
7
8
9Removing the oil cooler
Engine oil
Oil cooler inlet hose
Bolt
Washer
Oil cooler
O-ring
Water pump outlet pipe
O-ring
Water jacket joint inlet hose
O-ring1
1
1
1
1
1
1
1
1Remove the parts in the order listed.
Drain.
Refer to “CHANGING THE ENGINE OIL”
in chapter 3.
10 Nm (1.0 m
kg, 7.2 ft
lb)
10 Nm (1.0 m
kg, 7.2 ft
lb)
63 Nm (6.3 m
kg, 46 ft
lb)
OIL COOLERCOOL
EAS00457
OIL COOLER
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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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7-1
FUEL INJECTION SYSTEMFI
19Atmospheric pressure
sensor
20Fuel injection system
relay
21Engine trouble warning
light
22Lean angle cut-off
switch
23Air cut-off valve
13Coolant temperature
sensor
14Spark plug
15Cylinder identification
sensor
16Pressure regulator
17Battery
18ECU
1Ignition coil
2Air filter case
3Intake temperature
sensor
4Fuel delivery hose
5Fuel tank
6Fuel pump
7Fuel return hose
8Intake air presure sen-
sor
9Throttle position sen-
sor
10Fuel injector
11Catalytic converter
12Crankshaft position
sensor
FUEL INJECTION SYSTEM
FUEL INJECTION SYSTEM
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7-3
FUEL INJECTION SYSTEMFI
1Main switch
4Fuse (main)
5Fuse (backup)
6Battery
7Fuse (fuel injection)
10Starting circuit cut-off relay
11Neutral switch
12Sidestand switch
13Fuel pump
14E.C.U.
15Ignition coil #1
16Ignition coil #2
17Ignition coil #3
18Ignition coil #4
19Spark plug
20Injector #1
21Injector #2
22Injector #3
23Injector #4
25Sub-throttle position sensor
26EXUP servo motor
27Speed sensor
28Coolant temperature sensor
29Intake air temperature sensor
31Crankshaft position sensor
32Throttle position sensor
33Intake air pressure sensor
34Atmospheric pressure sensor
35Cylinder identification sensor
36Lean angle cut-off switch
43Multi function meter
53Engine stop switch
73Fuse (ignition)
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