Project Great White - Overhaul Build - Yamaha R1 Forum: YZF-R1 Forums

04-06 R1 Mechanical Help Mechanical and Critical Issues for the 04-06 R1

 53Likes
Reply
 
LinkBack Thread Tools Display Modes
post #1 of 155 (permalink) Old 07-10-2016, 07:51 PM Thread Starter
2004 R1
 
J_MacR1's Avatar
 
Join Date: Mar 2016
Posts: 92
Project Great White - Overhaul Build

So I had the infamous stator failure....bits everywhere in the engine, making knocking noises found magnet fragments all the way in the cylinder block, decided to rebuild and clean anything and everything.

Broke it down to the big end bearings, replaced all necessary "failure" parts. Cam chain good, tensioner good, cams good, Pistons good minor carbon build but no oil burn, oil pump good, water pump minor rust in tubing but not failing. Any who below is pics of the progress and video with fairing was the day before I tore down, video with tank up is day I ended the rebuild. Any help is appreciated.

Replaced with 06 clutch and clutch boss
Replaced with 06 stator rotor
Replaced with 06 stator


Things I think may be:
1. Timing off some how
2. Starter
3. Spark plug wires? Brand new spark plugs ~1000 miles
4. Fuel pump?
5. Fuel lines?

Thanks everyone



Sent from my iPhone using Tapatalk
J_MacR1 is offline  
Sponsored Links
Advertisement
 
post #2 of 155 (permalink) Old 07-10-2016, 08:05 PM Thread Starter
2004 R1
 
J_MacR1's Avatar
 
Join Date: Mar 2016
Posts: 92


Here are the vids they wouldn't compress on this app


Sent from my iPhone using Tapatalk
J_MacR1 is offline  
post #3 of 155 (permalink) Old 07-10-2016, 08:06 PM Thread Starter
2004 R1
 
J_MacR1's Avatar
 
Join Date: Mar 2016
Posts: 92
Damnit also failed to mention....5VY 2004


Sent from my iPhone using Tapatalk
J_MacR1 is offline  
 
post #4 of 155 (permalink) Old 07-10-2016, 10:22 PM
Is there anybody out there?
 
Join Date: May 2003
Location: Boise, ID
Posts: 3,790
At least determine if it's electrical or fuel related. Pull a plug and see if it sparks.

Mark
Sharksawyer is offline  
post #5 of 155 (permalink) Old 07-25-2016, 07:29 PM Thread Starter
2004 R1
 
J_MacR1's Avatar
 
Join Date: Mar 2016
Posts: 92
Update to the progress:
Took starter out rebuilt, good
Spark good
Timing good
CCT good
Fuses good
No trouble codes
No odd numbers in diag mode....
Here are some of the new vids for you guys.


Sent from my iPhone using Tapatalk
J_MacR1 is offline  
post #6 of 155 (permalink) Old 07-28-2016, 04:16 PM Thread Starter
2004 R1
 
J_MacR1's Avatar
 
Join Date: Mar 2016
Posts: 92
Update:
Compression is way off and cylinder 4 isn't registering at all on the compression test.....great. So looks like either valves/piston rings/gasket (which ruling out due to being new) so looks like I'm breaking the cases again....


Sent from my iPhone using Tapatalk
J_MacR1 is offline  
post #7 of 155 (permalink) Old 07-28-2016, 04:27 PM
I eat my R1
 
Join Date: Jul 2013
Location: Drain, Oregon
Posts: 835
Project Great White - Overhaul Build

Quote:
Originally Posted by J_MacR1 View Post
Update:
Compression is way off and cylinder 4 isn't registering at all on the compression test.....great. So looks like either valves/piston rings/gasket (which ruling out due to being new) so looks like I'm breaking the cases again....


Sent from my iPhone using Tapatalk
Do yourself a favor and do a cylinder leak down before you tear it apart... If you don't know how check YouTube
If your compression tester has a removable hose attach it to your air compressor line and put air in the cylinder at TDC and see if it's going out the exhaust or intake or crankcase breather. Did you put knew valves in and not check clearances? Or mix up the pucks locations?
milheim05 likes this.
Zac Agee is offline  
post #8 of 155 (permalink) Old 07-28-2016, 06:32 PM
R1, "A Superior Addiction"
 
cyclepsycho7's Avatar
 
Join Date: Jan 2006
Location: NY
Posts: 13,194
How many miles did you have on the bike?


To view links or images in signatures your post count must be 1 or greater. You currently have 0 posts.
Lucky 13 Squadron


To view links or images in signatures your post count must be 1 or greater. You currently have 0 posts.
cyclepsycho7 is online now  
post #9 of 155 (permalink) Old 07-29-2016, 06:21 PM Thread Starter
2004 R1
 
J_MacR1's Avatar
 
Join Date: Mar 2016
Posts: 92
Quote:
Originally Posted by Zac Agee View Post
Do yourself a favor and do a cylinder leak down before you tear it apart... If you don't know how check YouTube
If your compression tester has a removable hose attach it to your air compressor line and put air in the cylinder at TDC and see if it's going out the exhaust or intake or crankcase breather. Did you put knew valves in and not check clearances? Or mix up the pucks locations?


Thanks Zac. I just finished the leak down and results:
Cyl 1 : 45% sound from intake and feel air
Cyl 2 : 55% sound from intake/exhaust and feel air
Cyl 3 : 60% sound from intake/exhaust and feel air
Cyl 4 : 80% sound from intake/exhaust and feel air

I set the gauge at 0 on out and the inlet was reading like 15psi. TDC on each piston and no air was heard through the breather or clutch case. So going to check clearances, pull the head, lap the valves on pretty much all 20 of them, put cams back in place check clearances again and shim what I have to. Hopefully this is my complete problem. I did NOT break down the head as i didn't "see" any issues with the valves or head....but with out any pressure and torquing on it I'm sure it broke a piece of carbon and lodged into it. I'm going to do another leak down before I start tear down of the head again too just to re record numbers and verify no piston ring issue.


Sent from my iPhone using Tapatalk
J_MacR1 is offline  
post #10 of 155 (permalink) Old 07-29-2016, 06:24 PM Thread Starter
2004 R1
 
J_MacR1's Avatar
 
Join Date: Mar 2016
Posts: 92
Quote:
Originally Posted by cyclepsycho7 View Post
How many miles did you have on the bike?


36,000 indicated but I'm estimating 30,000 due to no speedo healer from the guy I bought it from. -1 +2 so it was off a good bit till I got a healer about 2 months ago.


Sent from my iPhone using Tapatalk
J_MacR1 is offline  
post #11 of 155 (permalink) Old 07-29-2016, 07:47 PM
I eat my R1
 
Join Date: Jul 2013
Location: Drain, Oregon
Posts: 835
Project Great White - Overhaul Build

Quote:
Originally Posted by J_MacR1 View Post
Quote:
Originally Posted by Zac Agee View Post
Do yourself a favor and do a cylinder leak down before you tear it apart... If you don't know how check YouTube
If your compression tester has a removable hose attach it to your air compressor line and put air in the cylinder at TDC and see if it's going out the exhaust or intake or crankcase breather. Did you put knew valves in and not check clearances? Or mix up the pucks locations?


Thanks Zac. I just finished the leak down and results:
Cyl 1 : 45% sound from intake and feel air
Cyl 2 : 55% sound from intake/exhaust and feel air
Cyl 3 : 60% sound from intake/exhaust and feel air
Cyl 4 : 80% sound from intake/exhaust and feel air

I set the gauge at 0 on out and the inlet was reading like 15psi. TDC on each piston and no air was heard through the breather or clutch case. So going to check clearances, pull the head, lap the valves on pretty much all 20 of them, put cams back in place check clearances again and shim what I have to. Hopefully this is my complete problem. I did NOT break down the head as i didn't "see" any issues with the valves or head....but with out any pressure and torquing on it I'm sure it broke a piece of carbon and lodged into it. I'm going to do another leak down before I start tear down of the head again too just to re record numbers and verify no piston ring issue.


Sent from my iPhone using Tapatalk
So you never had the head disassembled?
Double check your cam timing then check valve clearances.. Might get lucky never know..
Can spray a little wd-40 in the cylinder and retest to help determine a ring issue
Zac Agee is offline  
post #12 of 155 (permalink) Old 07-30-2016, 02:19 AM Thread Starter
2004 R1
 
J_MacR1's Avatar
 
Join Date: Mar 2016
Posts: 92
Quote:
Originally Posted by Zac Agee View Post
So you never had the head disassembled?
Double check your cam timing then check valve clearances.. Might get lucky never know..
Can spray a little wd-40 in the cylinder and retest to help determine a ring issue


No never disassembled the head. I should have....but didn't. And I'm hoping to get a couple hours in on it starting Monday through next week. But I will update you guys then.


Sent from my iPhone using Tapatalk
J_MacR1 is offline  
post #13 of 155 (permalink) Old 08-01-2016, 02:19 PM Thread Starter
2004 R1
 
J_MacR1's Avatar
 
Join Date: Mar 2016
Posts: 92
Update:
Swapped the 04 head with an 06 I had bought earlier on in the build, clearances good, and right after install BEFORE cams went on leak down was within acceptable range 10-18% leakage. Put cams in according to manual at TDC CYL 1 and alignment dots were almost spot on off by maybe a quarter tooth turn on the intake side. Re torqued everything buttoned up radiator, tubing, and wiring harnesses. Tank installed and looked over codes again, all from where I had everything in hooked. Good.

Cranked up on first go......however didn't sound too pretty. Then shut off on its own about 45 seconds later....won't crank again....correction won't start. It cranks fine just no bang


Sent from my iPhone using Tapatalk
J_MacR1 is offline  
post #14 of 155 (permalink) Old 08-01-2016, 06:18 PM
I eat my R1
 
Join Date: Jul 2013
Location: Drain, Oregon
Posts: 835
Project Great White - Overhaul Build

Didn't sound to pretty could mean anything lol! Like missing on one cylinder, knocking, rattling?
If it just sounds like a miss check the plugs and coils then fuel
Zac Agee is offline  
post #15 of 155 (permalink) Old 08-02-2016, 09:15 PM Thread Starter
2004 R1
 
J_MacR1's Avatar
 
Join Date: Mar 2016
Posts: 92
Quote:
Originally Posted by Zac Agee View Post
Didn't sound to pretty could mean anything lol! Like missing on one cylinder, knocking, rattling?
If it just sounds like a miss check the plugs and coils then fuel


Thinking I didn't install CCT correctly, so I'm checking on that tomorrow after work. And it's ticking coming from the right side motor, can't be bearings as they looked great when I was checking each one. No scoring or discoloration. On journal bearings or rod bearings. And I'm firing on all cylinders (all header pipes were hot at the exit.) started it again this morning and did the same thing - however it shut off immediately after I turned the throttle even a little bit, then wouldn't start back up, just turned over constantly after about 3 turns made a sputter every time. Which has me thinking: Fuel pump, maybe sitting for 2 months did something?

Anyway after watching videos online on "ticking" I believe it's the CCT or something not set correctly on valves. So I'm going to pull the cover AGAIN, to see if I skipped a tooth and correct the CCT (I didn't set the pin at full close as per manual). Also going to try and re sync the TB's while I'm in there.

I'm just ready to ride........


Sent from my iPhone using Tapatalk
J_MacR1 is offline  
post #16 of 155 (permalink) Old 08-03-2016, 05:00 PM Thread Starter
2004 R1
 
J_MacR1's Avatar
 
Join Date: Mar 2016
Posts: 92

Where I put my hand I have slight vibration so thinking CC or CCT


Sent from my iPhone using Tapatalk
J_MacR1 is offline  
post #17 of 155 (permalink) Old 08-03-2016, 05:49 PM
I eat my R1
 
Join Date: Jul 2013
Location: Drain, Oregon
Posts: 835
Project Great White - Overhaul Build

Quote:
Originally Posted by J_MacR1 View Post

Where I put my hand I have slight vibration so thinking CC or CCT


Sent from my iPhone using Tapatalk
That sounds way louder then a cct! Sounds more like a valve issue, bent or hitting piston possibly, id do another cylinder leak down and see before I ran it anymore..
And the way it dies seems like it's bleeding off compression then stalling

Last edited by Zac Agee; 08-03-2016 at 05:52 PM.
Zac Agee is offline  
post #18 of 155 (permalink) Old 08-03-2016, 08:28 PM Thread Starter
2004 R1
 
J_MacR1's Avatar
 
Join Date: Mar 2016
Posts: 92
Thanks again zac for the help, I'm just thankful that it "is" actually running although bad it's better than not so I can pin point the issue, rules out fuel pump I think. I'll do another leak down in the morning and post my findings.


Sent from my iPhone using Tapatalk
J_MacR1 is offline  
post #19 of 155 (permalink) Old 08-03-2016, 08:59 PM
Save a life, grope your wife!
 
hooligan998's Avatar
 
Join Date: Apr 2007
Location: Chester, VA
Posts: 1,255
I can't see videos here from work, but from what I can read I'd be willing to bet that upon reassembly you didn't get the CCT to engage properly before cranking the engine over with the starter and skipped a tooth on one of the cams. It's enough to keep the bike from starting, but just enough that hard parts don't hit. I don't know if you turned the engine over by hand first or not, but you should and do it slowly. You will see the cam chain tension when it engages. A light tap with a rawhide or other soft material mallet on the CCT will help disengage the holding mechanism for the CCT when doing this.

FWIW, I made this same mistake when putting the head back on my 07. It would crank all day but wouldn't catch and idle. The problem ended up being that the cam chain skipped a tooth on the exhaust cam gear when I cranked it over with the starter with out making sure the CCT was properly engaged.
J_MacR1 likes this.
hooligan998 is offline  
post #20 of 155 (permalink) Old 08-03-2016, 09:11 PM Thread Starter
2004 R1
 
J_MacR1's Avatar
 
Join Date: Mar 2016
Posts: 92
Quote:
Originally Posted by hooligan998 View Post
I can't see videos here from work, but from what I can read I'd be willing to bet that upon reassembly you didn't get the CCT to engage properly before cranking the engine over with the starter and skipped a tooth on one of the cams. It's enough to keep the bike from starting, but just enough that hard parts don't hit. I don't know if you turned the engine over by hand first or not, but you should and do it slowly. You will see the cam chain tension when it engages. A light tap with a rawhide or other soft material mallet on the CCT will help disengage the holding mechanism for the CCT when doing this.



FWIW, I made this same mistake when putting the head back on my 07. It would crank all day but wouldn't catch and idle. The problem ended up being that the cam chain skipped a tooth on the exhaust cam gear when I cranked it over with the starter with out making sure the CCT was properly engaged.


Thanks hooligan, i did install it incorrectly. I put it back in at full extension. So that is very possible. Tonight I pulled it out drained the oil in the cavity and pushed it in and clipped the retaining clip over it - then took the shaft cover off and "manually" slapped at the chain and "click" it engaged perfectly. However it had turned over before this point so it may have already skipped a tooth.

I'm pulling the radiator and cover tomorrow during my leak down to see if I've damaged anything and any leakage through the valves. While I'm in I'll also post if i indeed skipped a tooth.

Would skipping a tooth still allow it to run? Minus the tapping everything else is operational.

When you do watch the vids: would it create that racket?

Again thank you for your help.


Sent from my iPhone using Tapatalk
J_MacR1 is offline  
Sponsored Links
Advertisement
 
Reply

Quick Reply
Message:
Options

Register Now



In order to be able to post messages on the Yamaha R1 Forum: YZF-R1 Forums forums, you must first register.
Please enter your desired user name, your email address and other required details in the form below.

User Name:
Password
Please enter a password for your user account. Note that passwords are case-sensitive.

Password:


Confirm Password:
Email Address
Please enter a valid email address for yourself.

Email Address:
OR

Log-in









Human Verification

In order to verify that you are a human and not a spam bot, please enter the answer into the following box below based on the instructions contained in the graphic.



Thread Tools
Show Printable Version Show Printable Version
Email this Page Email this Page
Display Modes
Linear Mode Linear Mode



Posting Rules  
You may post new threads
You may post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are On
Pingbacks are On
Refbacks are On

 
For the best viewing experience please update your browser to Google Chrome