User manual YAMAHA YZF-R1SC SERVICE MANUAL

[. . . ] EAS00010 YZF-R1S/YZF-R1SC SERVICE MANUAL 2003 by Yamaha Motor Corporation, U. S. A. First edition, December 2003 All rights reserved. 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. [. . . ] Apply Mechanic's blueing dye (Dykem) onto the valve face. Install the valve into the cylinder head. Press the valve through the valve guide and onto the valve seat to make a clear impression. If the valve seat width is out of specification, reface and lap the valve seat. EAS00241 CHECKING THE VALVE SPRINGS The following procedure applies to all of the valve springs. Measure: S valve spring free length a Out of specification !Valve spring free length Intake valve spring 39. 3 mm (1. 55 in) <Limit>: 37. 3 mm (1. 47 in) Exhaust valve spring 39. 3 mm (1. 55 in) <Limit>: 37. 3 mm (1. 47 in) 5-31 VALVES AND VALVE SPRINGS ENG 2. Measure: S compressed valve spring force a Out of specification !b Installed length Compressed valve spring force (installed) Intake valve spring 145. 9 X 167. 9 N (14. 88 X 17. 12 kg, 32. 80 X 37. 74 lb) at 32. 65 mm (1. 285 in) Exhaust valve spring 164. 1 X 188. 9 N (16. 73 X 19. 26 kg, 36. 89 X 42. 46 lb) at 32. 82 mm (12. 92 in) 3. Measure: S valve spring tilt a Out of specification !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. Check: S valve lifter Damage/scratches !Replace the valve lifters and cylinder head. EAS00245 INSTALLING THE VALVES The following procedure applies to all of the valves and related components. Deburr: S valve stem end (with an oil stone) 5-32 VALVES AND VALVE SPRINGS ENG 2. Lubricate: S valve stem 1 S valve stem seal 2 (with the recommended lubricant) Recommended lubricant Molybdenum disulfide oil 3. Install: S valve 1 S lower spring seat 2 S valve stem seal 3 S valve spring 4 S upper spring seat 5 (into the cylinder head) NOTE: Install the valve spring with the larger pitch a facing up. b Smaller pitch NOTE: Make sure that each valve is installed in its original place. Right and left intake valve(-s): "5VY :" Middle intake valve(-s): "5VY . " Exhaust valve(-s): "5VY" 4. Install: S valve cotters 1 NOTE: Install 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 5-33 VALVES AND VALVE SPRINGS ENG 5. To secure the valve cotters onto the valve stem, lightly tap the valve tip with a soft-face hammer. CAUTION: Hitting the valve tip with excessive force could damage the valve. 6. Install: S valve pad 1 S valve lifter 2 NOTE: S Lubricate the valve lifter and valve pad with molybdenum disulfide oil. S The valve lifter must move smoothly when rotated with a finger. S Each valve lifter and valve pad must be reinstalled in its original position. 5-34 STARTER CLUTCH AND GENERATOR ENG STARTER CLUTCH AND GENERATOR STATOR COIL ASSEMBLY 10 Nm (1. 0 mSkg, 7. 2 ftSlb) 14 Nm (1. 4 mSkg, 10 ftSlb) 12 Nm (1. 2 mSkg, 8. 7 ftSlb) 22 Nm (2. 2 mSkg, 16 ftSlb) 12 Nm (1. 2 mSkg, 8. 7 ftSlb) 10 Nm (1. 0 mSkg, 7. 2 ftSlb) 12 Nm (1. 2 mSkg, 8. 7 ftSlb) 22 Nm (2. 2 mSkg, 16 ftSlb) 10 Nm (1. 0 mSkg, 7. 2 ftSlb) Order Job/Part Removing the stator coil assembly Rider seat Fuel tank Left side cowling Bottom cowlings Engine oil Q'ty Remarks Remove the parts in the order listed. [. . . ] S The oil level warning light indicate the condition code. Condition code Refer to *1 Refer to *2 *1 Condition code Fuel level warning light *2 Condition code Oil level warning light 8-53 SELF-DIAGNOSIS TROUBLESHOOTING The warning light starts to indicate the self-diagnosis sequence. oil level switch NOTE: S Before troubleshooting, remove the following part(-s): 1. fuel tank S Troubleshoot with the following special tool(-s). [. . . ]