steering YAMAHA YZF-R1S 2004 User Guide

3-53
CHECKING AND ADJUSTING THE STEERING HEAD /
CHECKING THE FRONT FORKCHK
ADJ
WARNING
Steering head tension
200
500 g
e. Repeat the above procedure on the opposite
handlebar.
f. If the steering head tension is out of specifi-
cation (both handlebars should be within
specification), remove the upper bracket and
loosen or tighten the upper ring nut.
g. Reinstall the upper bracket and measure the
steering head tension again as described
above.
h. Repeat the above procedure until the steer-
ing head tension is within specification.
i. Grasp the bottom of the front fork legs and
gently rock the front fork.
Binding / looseness
Adjust the steering
head.
EAS00150
CHECKING THE FRONT FORK
1. Stand the motorcycle on a level surface.
Securely support the motorcycle so that
there is no danger of it falling over.
2. Check:

inner tube
1
Damage / scratches
Replace.

oil seal
2
Oil leakage
Replace.
3. Hold the motorcycle upright and apply the
front brake.
4. Check:

front fork operation
Push down hard on the handlebars several
times and check if the front fork rebounds
smoothly.
Rough movement
Repair.
Refer to “FRONT FORK” in chapter 4.
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4-57
HANDLEBARSCHAS
Order Job / Part Q’ty Remarks
16
17
18
19
20
21
22
23
24Brake master cylinder
Steering damper
Handlebar pinch bolt
Upper bracket bolt
Upper bracket pinch bolt
Steering stem nut
Upper bracket
Left handlebar
Right handlebar1
1
2
2
2
1
1
1
1
For assembly, reverse the disassembly
procedure.
113 Nm (11.3 m
kg, 82 ft
lb)
17 Nm (1.7 m
kg, 12 ft
lb)
11 Nm (1.1 m
kg, 8.0 ft
lb)
23 Nm (2.3 m
kg, 17 ft
lb)
13 Nm (1.3 m
kg, 9.4 ft
lb)
23 Nm (2.3 m
kg, 17 ft
lb)3.8 Nm (0.38 m
kg, 2.7 ft
lb)
3.8 Nm (0.38 m
kg, 2.7 ft
lb)
3.8 Nm (0.38 m
kg, 2.7 ft
lb)
13 Nm (1.3 m
kg, 9.4 ft
lb)
26 Nm (2.6 m
kg, 19 ft
lb)
17 Nm (1.7 m
kg, 12 ft
lb)
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4-60
HANDLEBARSCHAS
NOTE:
WARNING
6. Install:

left handlebar switch
1
Align the projection a on the left handlebar
switch with the hole
b in the left handlebar.
7. Install:

handlebar grip
a. Apply a thin coat of rubber adhesive onto the
end of the left handlebar.
b. Slide the handlebar grip over the end of the
left handlebar.
c. Wipe off any excess rubber adhesive with a
clean rag.
Do not touch the handlebar grip until the
rubber adhesive has fully dried.
8. Adjust:

clutch cable free play
Refer to “ADJUSTING THE CLUTCH
CABLE FREE PLAY” in chapter 3.
Clutch cable free play
(at the end of the clutch lever)
10
15 mm (0.39
0.59 in)
9. Adjust:

throttle cable free play
Refer to “ADJUSTING THE THROTTLE
CABLE FREE PLAY” in chapter 3.
Throttle cable free play
(at the flange of the throttle grip)
3
5 mm (0.12
0.20 in)
CHECKING THE STEERING DAMPER
1. Check:

steering damper body
Damage / oil leaks
Replace.
(It replace with the assembly.)

steering damper rod
Bends / scratch
Replace.
(It replace with the assembly.)

bearing
Damage /pitting
Replace.
(It replace with the assembly.)
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4-61
Order Job / Part Q’ty Remarks
1
2
3
4
5
6
7
8
9
10Removing the under bracket
Front wheel
Front cowling and side cowling
Front fork legs
Main switch connector
Upper bracket bolt
Left handlebar assembly
Right handlebar assembly
Steering stem nut
Upper bracket
Under bracket panel
Brake hose holder bolt
Lock washer
Upper ring nut2
2
1
1
1
1
1
1
1
1Remove the parts in the order listed.
Refer to “FRONT WHEEL AND BRAKE
DISCS”.
Refer to “COWLINGS” in chapter 3.
Refer to “FRONT FORK”.
Disconnect.
For installation, reverse the removal
procedure.
38 Nm (0.38 m
kg, 2.75 ft
lb)113 Nm (11.3 m
kg, 82 ft
lb)
52 Nm (5.2 m
kg, 38 ft
lb)
18 Nm (1.8 m
kg, 13 ft
lb)
1st
2nd23 Nm (2.3 m
kg, 17 ft
lb)
23 Nm (2.3 m
kg, 17 ft
lb)
7 Nm (0.7 m
kg, 5.1 ft
lb)
17 Nm (1.7 m
kg, 12 ft
lb)
STEERING HEADCHAS
EAS00676
STEERING HEAD
UNDER BRACKET
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4-62
STEERING HEADCHAS
Order Job / Part Q’ty Remarks
11
12
13
14
15
16
17
18
19Rubber washer
Lower ring nut
Under bracket
Bearing cover
Bearing inner race
Upper bearing
Lower bearing
Dust seal
Bearing outer race1
1
1
1
2
1
1
1
2
For assembly, reverse the disassembly
procedure.
38 Nm (0.38 m
kg, 2.75 ft
lb)113 Nm (11.3 m
kg, 82 ft
lb)
52 Nm (5.2 m
kg, 38 ft
lb)
18 Nm (1.8 m
kg, 13 ft
lb)
1st
2nd23 Nm (2.3 m
kg, 17 ft
lb)
23 Nm (2.3 m
kg, 17 ft
lb)
7 Nm (0.7 m
kg, 5.1 ft
lb)
17 Nm (1.7 m
kg, 12 ft
lb)
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4-63
STEERING HEADCHAS
WARNING
WARNING
EAS00677
REMOVING THE UNDER BRACKET
1. Stand the motorcycle on a level surface.
Securely support the motorcycle so that
there is no danger of it falling over.
2. Remove:

ring nut
1
(with the steering nut wrench 2)
Steering nut wrench
90890–01403, YU-33975
Securely support the lower bracket so that
there is no danger of it falling.
EAS00681
CHECKING THE STEERING HEAD
1. Wash:

bearings

bearing races
Recommended cleaning solvent
Kerosene
2. Check:

bearings
1

bearing races 2
Damage / pitting
Replace.
3. Replace:

bearings

bearing races
a. Remove the bearing races
1 from the steer-
ing head pipe with a long rod
2 and hammer.
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4-64
STEERING HEADCHAS
CAUTION:
NOTE:
NOTE:
NOTE: b. Remove the bearing race
3 from the lower
bracket with a floor chisel
4 and hammer.
c. Install a new rubber seal and new bearing
races.
If the bearing race is not installed properly,
the steering head pipe could be damaged.

Always replace the bearings and bearing
races as a set.

Whenever the steering head is disassembled,
replace the rubber seal.
4. Check:

upper bracket

lower bracket
(along with the steering stem)
Bends / cracks / damage
Replace.
EAS00683
INSTALLING THE STEERING HEAD
1. Lubricate:

upper bearing

lower bearing

bearing races
Recommended lubricant
Lithium-soap-based grease
2. Install:

lower ring nut
1

rubber washer 2

upper ring nut 3

lock washer 4
Refer to “CHECKING THE STEERING
HEAD” in chapter 3.
3. Install:

upper bracket

steering stem nut
Temporarily tighten the steering stem nut.
4. Install:

front fork legs
Refer to “INSTALLING THE FRONT FORK
LEGS”.
Temporarily tighten the upper and lower bracket
pinch bolts.
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9-5
FAULTY FRONT FORK LEGS / UNSTABLE HANDLING
TRBL
SHTG
MALFUNCTION

Bent or damaged inner tube

Bent or damaged outer tube

Damaged fork spring

Worn or damaged outer tube bushing

Bent or damaged damper rod

Incorrect oil viscosity

Incorrect oil level
Rear shock absorber assembly(-ies)

Faulty rear shock absorber spring

Leaking oil or gas
Tire(s)

Uneven tire pressures (front and rear)

Incorrect tire pressure

Uneven tire wear
Wheel(s)

Incorrect wheel balance

Deformed cast wheel

Damaged wheel bearing

Bent or loose wheel axle

Excessive wheel runout
Frame

Bent frame

Damaged steering head pipe

Improperly installed bearing race
EAS00861
FAULTY FRONT FORK LEGS
LEAKING OIL

Bent, damaged or rusty inner tube

Cracked or damaged outer tube

Improperly installed oil seal

Damaged oil seal lip

Incorrect oil level (high)

Loose damper rod assembly bolt

Damaged damper rod assembly bolt
copper washer

Cracked or damaged cap bolt O-ring
EAS00863
UNSTABLE HANDLING
Handlebars

Bent or improperly installed right handlebar

Bent or improperly installed left handlebar
Steering head components

Improperly installed upper bracket

Improperly installed under bracket
(improperly tightened ring nut)

Bent steering stem

Damaged ball bearing or bearing race
Front fork leg(s)

Uneven oil levels (both front fork legs)

Unevenly tensioned fork spring (both front
fork legs)

Broken fork spring

Bent or damaged inner tube

Bent or damaged outer tube
Swingarm

Worn bearing or bushing

Bent or damaged swingarm
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