User manual YAMAHA YZF-R1SC SERVICE MANUAL

[. . . ] EAS00010 YZF-R1S/YZF-R1SC SERVICE MANUAL 2003 by Yamaha Motor Corporation, U. S. A. Any reproduction or unauthorized use without the written permission of Yamaha Motor Corporation, U. S. A. P/N LIT-11616-17-55 EAS00030 NOTICE This manual was produced by the Yamaha Motor Company, Ltd. It is not possible to include all the knowledge of a mechanic in one manual. [. . . ] Remove: S cylinder head nuts S cylinder head bolts NOTE: S Loosen the nuts in the proper sequence as shown. After all of the nuts are fully loosened, remove them. EAS00227 CHECKING THE CYLINDER HEAD 1. Eliminate: S combustion chamber carbon deposits (with a rounded scraper) NOTE: Do not use a sharp instrument to avoid damaging or scratching: S spark plug bore threads S valve seats 2. Place a straightedge 1 and a thickness gauge 2 across the cylinder head. Place a 400 X 600 grit wet sandpaper on the surface plate and resurface the cylinder head using a figure-eight sanding pattern. NOTE: To ensure an even surface, rotate the cylinder head several times. 5-23 CYLINDER HEAD EAS00233 ENG INSTALLING THE CYLINDER HEAD 1. Check: S cylinder head bolts 1 8 Nm (0. 8 mSkg, 5. 8 ftSlb) NOTE: Retighten the cylinder head bolts to specification, before installing the cylinder head. 2. Install: S cylinder head NOTE: Pass the timing chain through the timing chain cavity. Tighten: S cylinder head nuts 1 X 10 19 Nm (1. 9 mSkg, 14 ftSlb) 1st 67 Nm (6. 7 mSkg, 48 ftSlb) 2nd S cylinder head bolts 11 12 12 Nm (1. 2 mSkg, 8. 7 ftSlb) NOTE: S First, tighten the nuts 1 X 10 to approximately 19 Nm (1. 9 mSkg, 14 ftSlb) with a torque wrench, and then tighten the 67 Nm (6. 7 mSkg, 48 ftSlb). S Tighten the cylinder head nuts in the proper tightening sequence as shown and torque them in two stages. Install: S exhaust camshaft S intake camshaft Refer to "INSTALLING THE CAMSHAFTS". 5-24 VALVES AND VALVE SPRINGS EAS00236 ENG VALVES AND VALVE SPRINGS Order Job/Part Removing the valves and valve springs Cylinder head Intake valve lifter Intake valve pad Intake valve cotter Intake valve upper spring seat Intake valve spring Intake valve oil seal Intake valve lower spring seat Intake valve Intake valve guide Q'ty Remarks Remove the parts in the order listed. Refer to "CYLINDER HEAD". 1 2 3 4 5 6 7 8 9 12 12 24 12 12 12 12 12 12 5-25 VALVES AND VALVE SPRINGS ENG Order 10 11 12 13 14 15 16 17 18 Job/Part Exhaust valve lifter Exhaust valve pad Exhaust valve cotter Exhaust valve upper spring seat Exhaust valve spring Exhaust valve oil seal Exhaust valve lower spring seat Exhaust valve Exhaust valve guide Q'ty 8 8 16 8 8 8 8 8 8 Remarks For installation, reverse the removal procedure. 5-26 VALVES AND VALVE SPRINGS EAS00237 ENG REMOVING THE VALVES The following procedure applies to all of the valves and related components. NOTE: Before removing the internal parts of the cylinder head (e. g. , valves, valve springs, valve seats), make sure the valves properly seal. 1. Remove: S valve lifter 1 S valve pad 2 NOTE: Make a note of the position of each valve lifter and valve pad so that they can be reinstalled in their original place. 2. Remove: S valve cotters 1 NOTE: Remove the valve cotters by compressing the valve spring with the valve spring compressor 2 and the valve spring compressor attachment 3. Valve spring compressor 90890-04019, YM-04019 Valve spring compressor attachment Intake valve 90890-04114, YM-4114 Exhaust valve 90890-04108, YM-4108 5-27 VALVES AND VALVE SPRINGS ENG 4. Remove: S upper spring seat 1 S valve spring 2 S valve stem seal 3 S lower spring seat 4 S valve 5 NOTE: Identify the position of each part very carefully so that it can be reinstalled in its original place. EAS00239 CHECKING THE VALVES AND VALVE GUIDES The following procedure applies to all of the valves and valve guides. Measure: S valve-stem-to-valve-guide clearance Valve-stem-to-valve-guide clearance = Valve guide inside diameter A ­ Valve stem diameter B Out of specification !Valve-stem-to-valve-guide clearance Intake 0. 0010 X 0. 0037 mm (0. 0004 X 0. 0015 in) <Limit>: 0. 08 mm (0. 0032 in) Exhaust 0. 025 X 0. 052 mm (0. 0010 X 0. 0020 in) <Limit>: 0. 10 mm (0. 0039 in) 2. Replace: S valve guide NOTE: To ease valve guide removal and installation, and to maintain the correct fit, heat the cylinder head to 100_C (212_F) in an oven. a. Install the new valve guide with the valve guide installer 2 and valve guide remover 1. After installing the valve guide, bore the valve guide with the valve guide reamer 3 to obtain the proper valve-stem-to-valve-guide clearance. 5-28 VALVES AND VALVE SPRINGS ENG NOTE: After replacing the valve guide, reface the valve seat. Valve guide remover Intake (4. 0 mm, 0. 16 in) 90890-04111 Exhaust (4. 5 mm, 0. 18 in) 90890-04116, YM-4116 Valve guide installer Intake (4. 0 mm, 0. 16 in) 90890-04112 Exhaust (4. 5 mm, 0. 18 in) 90890-04117, YM-4117 Valve guide reamer Intake (4. 0 mm, 0. 16 in) 90890-04113 Exhaust (4. 5 mm, 0. 18 in) 90890-04118, YM-4118 3. [. . . ] S Connect the pocket tester ( 1) and battery (12 V) to the starting circuit cut-off relay coupler as shown. Fuel pump resistance S Disconnect the fuel pump coupler from the wire harness. Fuel pump resistance 0. 2 X 3. 0 at 20_C (68_F) S Does the starting circuit cut-off relay have continuity between red and red/blue?S Is the fuel system's wiring properly connected and without defects? [. . . ]