2004 YAMAHA YZF-R1SC Service Manual

5-11
Order Job / Part Q’ty Remarks
1
2
3
4Removing the cylinder head cover
Fuel tank
Side and bottom cowlings
Throttle body assembly
Radiator assembly
Air cut-off valve
Ignition coil
Spark plug
Cylinder head cover
Cylinder head cover gasket4
4
1
1Remove the parts in the order listed.
Refer to “FUEL TANK” in chapter 3.
Refer to “COWLINGS” in chapter 3.
Refer to “THROTTLE BODIES” in
chapter 7.
Refer to “RADIATOR” in chapter 3.
Refer to “AIR INDUCTION SYSTEM” in
chapter 7.
13 Nm (1.3 m
kg, 9.4 ft
lb)
8 Nm (0.8 m
kg, 5.7 ft
lb)
12 Nm (1.2 m
kg, 8.7 ft
lb)
CAMSHAFTENG
EAS00194
CAMSHAFT
CYLINDER HEAD COVER
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5-12
CAMSHAFTENG
Order Job / Part Q’ty Remarks
5
6
7Timing chain guide (top side)
Cylinder identification sensor
O-ring1
1
1
For installation, reverse the removal
procedure.
13 Nm (1.3 m
kg, 9.4 ft
lb)
12 Nm (1.2 m
kg, 8.7 ft
lb)
8 Nm (0.8 m
kg, 5.7 ft
lb)
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5-13
Order Job / Part Q’ty Remarks
1
2
3
4
5
6
7
8
9
10Removing the camshafts
Pickup rotor cover
Camshaft sprocket bolt
Timing chain tensioner
Timing chain tensioner O-ring
Intake camshaft cap
Dowel pin
Exhaust camshaft cap
Dowel pin
Intake camshaft
Exhaust camshaft
Camshaft sprocket4
1
1
3
6
3
6
1
1
2Remove the parts in the order listed.
Refer to “CRANKSHAFT POSITION
SENSOR AND PICKUP ROTOR”.
Loosen.
Refer to “REMOVING THE
CAMSHAFTS”.
For installation, reverse the removal
procedure.
During removal, the dowel pins may still
be connected to the camshaft caps.
NOTE:
10 Nm (1.0 m
kg, 7.2 ft
lb)
24 Nm (2.4 m
kg, 17 ft
lb)
24 Nm (2.4 m
kg, 17 ft
lb)
10 Nm (1.0 m
kg, 7.2 ft
lb)10 Nm (1.0 m
kg, 7.2 ft
lb)
CAMSHAFTENG
EAS00196
CAMSHAFTS
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5-14
CAMSHAFTENG
NOTE:
CAUTION:
EAS00198
REMOVING THE CAMSHAFTS
1. Remove:

pickup rotor cover
Refer to “CRANKSHAFT POSITION SEN-
SOR AND PICKUP ROTOR”.
2. Align:

“T” mark
a on the pickup rotor
(with the crankcase mating surface
b)
a. Turn the crankshaft clockwise.
b. When piston #1 is at TDC on the compres-
sion stroke, align the “T” mark
a on the pick-
up rotor with the crankcase mating surface
b.
TDC on the compression stroke can be found
when the camshaft lobes are turned away from
each other.
3. Loosen:

camshaft sprocket bolts
1
Camshaft wrench
90890-04143
4. Remove:

timing chain tensioner
1

O-ring
5. Remove:

camshaft caps
1

dowel pins
To prevent damage to the cylinder head,
camshafts or camshaft caps, loosen the
camshaft cap bolts in stages and in a criss-
cross pattern, working from the outside in.
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5-15
CAMSHAFTENG
NOTE:
6. Remove:

intake camshaft
1

exhaust camshaft 2
To prevent the timing chain from falling into the
crankcase, fasten it with a wire
3.
7. Remove:

camshaft sprockets
EAS00204
CHECKING THE CAMSHAFTS
1. Check:

camshaft lobes
Blue discoloration / pitting / scratches
Re-
place the camshaft.
2. Measure:

camshaft lobe dimensions
a and b
Out of specification
Replace the cam-
shaft.
Camshaft lobe dimension limit
Intake camshaft
a 32.85
32.95 mm
(1.293
1.297 in)
: 32.75 mm (1.289 in)
b 25.14
25.24 mm
(0.990
0.994 in)
: 25.04 mm (0.986 in)
Exhaust camshaft
a 30.75
30.85 mm
(1.211
1.215 in)
: 30.65 mm (1.207 in)
b 23.09
23.19 mm
(0.909
0.913 in)
: 22.99 mm (0.905 in)
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5-16
CAMSHAFTENG
NOTE:
3. Measure:

camshaft runout
Out of specification
Replace.
Camshaft runout limit
0.03 mm (0.0012 in)
4. Measure:

camshaft-journal-to-camshaft-cap clear-
ance
Out of specification
Measure the camshaft
journal diameter.
Camshaft-journal-to-camshaft-
cap clearance
0.028
0.062 mm
(0.0011
0.0024 in)
a. Install the camshaft into the cylinder head
(without the dowel pins and camshaft caps).
b. Position strip of Plastigauge
 1 onto the
camshaft journal as shown.
c. Install the dowel pins and camshaft caps.

Tighten the camshaft cap bolts in stages and in
a crisscross pattern, working from the inner
caps out.

Do not turn the camshaft when measuring the
camshaft journal-to-camshaft cap clearance
with the Plastigauge
.
Camshaft cap bolt
10 Nm (1.0 m
kg, 7.2 ft
lb)
d. Remove the camshaft caps and then mea-
sure the width of the Plastigauge
 1.
5. Measure:

camshaft journal diameter
a
Out of specification
Replace the cam-
shaft.
Within specification
Replace the cylinder
head and the camshaft caps as a set.
Camshaft journal diameter
22.459
22.472 mm
(0.8842
0.8847 in)
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5-17
CAMSHAFTENG
NOTE:
EAS00208
CHECKING THE TIMING CHAIN, CAMSHAFT
SPROCKETS, AND TIMING CHAIN GUIDES
The following procedure applies to all of the
camshaft sprockets and timing chain guides.
1. Check:

timing chain
1
Damage / stiffness
Replace the timing
chain and camshaft sprockets as a set.
2. Check:

camshaft sprocket
More than 1 / 4 tooth wear
a
Replace the
camshaft sprockets and the timing chain as a
set.
a1 / 4 tooth
bCorrect
1Timing chain roller
2Camshaft sprocket
3. Check:

timing chain guide (exhaust side)
1

timing chain guide (intake side) 2

timing chain guide (top side) 3
Damage / wear
Replace the defective
part(s).
CHECKING THE TIMING CHAIN TENSIONER
1. Remove:

timing chain tensioner housing
1

timing chain tensioner rod 2

timing chain tensioner spring 3
Squeeze the timing chain tensioner clip, and
then remove the timing chain tensioner spring
and timing chain tensioner rod.
2. Check:

timing chain tensioner housing

timing chain tensioner rod

timing chain tensioner spring
Damage / wear
Replace.
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5-18
CAMSHAFTENG
NOTE:
NOTE:
NOTE:
3. Install:

timing chain tensioner spring

timing chain tension rod
1
Prior to installing the timing chain tensioner rod,
drain the engine oil from the timing chain ten-
sioner housing.
a. Install the timing chain tensioner spring and
timing chain tensioner rod
1.
b. Squeeze the timing chain tensioner clip
2
and push the timing chain tensioner rod 3.
When the timing chain tensioner rod
3 is
pushed while holding the grip of the timing chain
tensioner clip
2, make sure not to release the
timing chain tensioner rod
3 before releasing
the timing chain tensioner clip
2. (Otherwise,
the timing chain tensioner rod
3 may run off.)
c. Hook the clip
4 to the timing chain tensioner
rod
3.
Hook the timing chain tensioner rod pin
5 to the
center of the clip
4. After the installation, check
that the clip
4 can come off by its own weight by
pushing the timing chain tensioner rod
3 at the
position of installation.
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