2004 YAMAHA YZF-R1SC checking oil

5-32
VALVES AND VALVE SPRINGSENG
2. Measure:

compressed valve spring force
a
Out of specification
Replace the valve
spring.
bInstalled length
Compressed valve spring force
(installed)
Intake valve spring
145.9
167.9 N
(14.88
17.12 kg,
32.80
37.74 lb) at
32.65 mm (1.285 in)
Exhaust valve spring
164.1
188.9 N
(16.73
19.26 kg,
36.89
42.46 lb) at
32.82 mm (12.92 in)
3. Measure:

valve spring tilt
a
Out of specification
Replace the valve
spring.
Spring tilt limit
Intake valve spring
1.7 mm (0.07 in)
Exhaust valve spring
1.7 mm (0.07 in)
EAS00242
CHECKING THE VALVE LIFTERS
The following procedure applies to all of the
valve lifters.
1. Check:

valve lifter
Damage / scratches
Replace the valve lift-
ers and cylinder head.
EAS00245
INSTALLING THE VALVES
The following procedure applies to all of the
valves and related components.
1. Deburr:

valve stem end
(with an oil stone)
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5-41
STARTER CLUTCH AND GENERATORENG
NOTE:
NOTE:
10 Nm (1.0 m
kg, 7.2 ft
lb)
INSTALLING THE STARTER CLUTCH
1. Install:

generator rotor
1

damper 2

driven gear 3

The hole side of the damper is installed to the
generator side.

Lubricate the engine oil
4.
2. Install:

starter clutch drive gear
1

collar 2

washer 3
Refer to “CHECKING THE STARTER
CLUTCH”.
3. Install:

washer
1

O-ring 2 New

spacer
3
Lubricate the engine oil to O-ring.
INSTALLING THE GENERATOR
1. Install:

idle gear shaft

idle gear
1

washer

idle gear shaft bolt
2
LOCTITE
2. Install:

generator rotor and starter clutch assembly
1
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5-54
CLUTCHENG
NOTE:
EAS00286
CHECKING THE PRESSURE PLATE
1. Check:

pressure plate
1
Cracks / damage
Replace.

bearing
2
Damage / wear
Replace.
EAS00287
CHECKING THE PULL LEVER SHAFT AND
PULL ROD
1. Check:

pull lever shaft pinion gear teeth
1

pull rod teeth 2
Damage / wear
Replace the pull rod and
pull lever shaft pinion gear as a set.
2. Check:

pull rod bearing
Damage / wear
Replace.
INSTALLING THE CLUTCH
1. Install:

clutch damper spring seat
1

clutch damper spring 2
2. Install:

friction plate 3
1

clutch plate 2 2
Lubricate the engine oil.
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5-61
SHIFT SHAFTENG
22 Nm (2.2 m
kg, 16 ft
lb)
NOTE: CHECKING THE SHIFT SHAFT
1. Check:

shift shaft
1
Bends / damage / wear
replace.

shift shaft spring
2

collar 3
Damage / wear
Replace.
CHECKING THE STOPPER LEVER
1. Check:

stopper lever
1
Bends / damage
Replace.
Roller turns roughly
Replace the stopper
lever.
INSTALLING THE SHIFT SHAFT
1. Install:

washer

stopper lever
1

stopper screw 2
LOCTITE

stopper lever spring 3
2. Install:

washer

collar

shift shaft spring
1

shift shaft 2

Mesh the stopper lever with the shift drum seg-
ment assembly.

Lubricate the oil seal lips with lithium soap
base grease.

Install the end of the shift shaft spring onto the
shift shaft spring stopper.
3. Install:

Washer
1

circlip 2 New
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5-66
OIL PAN AND OIL PUMPENG
NOTE:
EAS00362
REMOVING THE OIL PAN
1. Remove:

oil level switch
1

oil pan 2

oil pan gasket

dowel pins
Loosen each bolt 1 / 4 of a turn at a time, in
stages and in a crisscross pattern. After all of
the bolts are fully loosened, remove them.
CHECKING THE SPROCKET AND CHAIN
1. Check:

oil / water pump assembly drive sprocket
1
Cracks / damage / wear
Replace the de-
fective part(-s).
2. Check:

oil / water pump assembly drive chain
1
Damage / stiffness
Replace the oil / water
pump assembly drive chain and oil / water
pump assembly drive sprocket as a set.
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5-67
OIL PAN AND OIL PUMPENG
EAS00364
CHECKING THE OIL PUMP
1. Check:

oil pump driven gear
1

oil pump rotor housing 2

oil pump cover
Cracks / damage / wear
Replace the de-
fective part(s).
2. Measure:

inner-rotor-to-outer-rotor-tip clearance
a

outer-rotor-to-oil-pump-housing clearance
b
1Inner rotor
2Outer rotor
3Oil pump housing
Inner-rotor-to-outer-rotor-tip
clearance
0.01
0.10 mm
(0.0004
0.0039 in)
: 0.18 mm (0.0071 in)
Outer-rotor-to-oil-pump-housing
clearance
0.09
0.15 mm
(0.0035
0.0059 in)
: 0.22 mm (0.0087 in)
3. Check:

oil pump operation
Rough movement
Repeat steps (1) and
(2) or replace the defective part(s).
EAS00365
CHECKING THE RELIEF VALVE
1. Check:

relief valve body
1

relief valve 2

spring 3

O-ring 4
Damage / wear
Replace the defective
part(s).
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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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