YAMAHA YZF-R1S 2004 Service Manual

4-54
FRONT FORKCHAS
NOTE:
WARNING
d. Press down on the spacer with the fork
spring compressor
1.
e. Pull up the rod puller and install the rod hold-
er
2 between the nut 3 and the spacer 4.
Use the side of the rod holder that is marked “B”.
Fork spring compressor
90890-01441, YM-01441
Rod holder
90890-01434, YM-01434
f. Remove the rod puller and adapter.
g. Install the nut
1 and position it as specified
b.
Distance
b
11 mm (0.43 in)
h. Set the cap bolt distance
c to specification.
Distance
c
13 mm (0.51 in)
i. Install the damper adjusting rod and cap bolt,
and then finger tighten the cap bolt.
j. Hold the cap bolt and tighten the nut to speci-
fication.
Nut
15 Nm (1.5 m
kg, 11 ft
lb)
k. Remove the rod holder and fork spring com-
pressor.

The fork spring is compressed.

Always use a new cap bolt O-ring.
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4-55
FRONT FORKCHAS
NOTE:
23 Nm (2.3 m
kg, 17 ft
lb)
23 Nm (2.3 m
kg, 17 ft
lb)
17 Nm (1.7 m
kg, 12 ft
lb)
26 Nm (2.6 m
kg, 19 ft
lb)
WARNING
EAS00662
INSTALLING THE FRONT FORK LEGS
The following procedure applies to both of the
front fork legs.
1. Install:

front fork leg
Temporarily tighten the upper and lower
bracket pinch bolts.
Make sure the inner fork tube is flush with the
top of the handlebar holder.
2. Tighten:

under bracket pinch bolt
1

cap bolt 2

handlebar pinch bolt 3

upper bracket pinch bolt 4
Make sure the brake hoses are routed prop-
erly.
3. Adjust:

spring preload

rebound damping

compression damping
Refer to “ADJUSTING THE FRONT FORK
LEGS” in chapter 3.
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4-56
Order Job / Part Q’ty Remarks
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15Removing the handlebars
Front cowling and side cowling
Left grip end
Handlebar grip
Clutch switch connector
Left handlebar switch
Clutch cable
Clutch lever
Right grip end
Throttle cable housing
Throttle cable
Throttle grip
Front brake light switch connector
Right handlebar switch
Clutch cable holder
Brake fluid reservoir tank
Brake master cylinder bracket1
1
2
1
1
1
1
1
2
1
2
1
1
1
1Remove the parts in the order listed.
Refer to “COWLINGS” in chapter 3.
Disconnect.
Disconnect.
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)
HANDLEBARSCHAS
EAS00665
HANDLEBARS
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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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4-58
HANDLEBARSCHAS
WARNING
NOTE:
NOTE:
WARNING
WARNING
EAS00667
REMOVING THE HANDLEBARS
1. Stand the motorcycle on a level surface.
Securely support the motorcycle so that
there is no danger of it falling over.
2. Remove:

handlebar grip
1
Blow compressed air between the left handle-
bar and the handlebar grip, and gradually push
the grip off the handlebar.
3. Remove:

throttle cable housing
1

throttle grip 2
While removing the throttle cable housing, pull
back the rubber cover
3.
EAS00669
CHECKING THE HANDLEBARS
1. Check:

left handlebar
1

right handlebar 2
Bends / cracks / damage
Replace.
Do not attempt to straighten bent handle-
bars as this may dangerously weaken them.
EAS00674
INSTALLING THE HANDLEBARS
1. Stand the motorcycle on a level surface.
Securely support the motorcycle so that
there is no danger of it falling over.
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4-59
HANDLEBARSCHAS
NOTE:
CAUTION:
NOTE:
NOTE:
NOTE: 2. Install:

right handlebar switch
1
Align the projection a on the right handlebar
switch with the hole
b in the right handlebar.
3. Install:

brake master cylinder holder
1

Install the brake master cylinder holder
with the “UP” mark facing up.

First, tighten the upper bolt, then the lower
bolt.

Align the mating surfaces of the brake master
cylinder holder with the punch mark
a in the
right handlebar.

There should be 2 mm (0.08 in) of clearance
between the right handlebar switch and the
brake master cylinder holder.
4. Install:

throttle grip

throttle cable housing
1

throttle cables
Align the projection
a on the throttle cable
housing with the hole
b in the right handlebar.
5. Install:

clutch lever holder
1
Align the slit in the clutch lever holder with the
punch mark
a in the left handlebar.
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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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