oil YAMAHA YZF-R1S 2004 Manual PDF

4-51
FRONT FORKCHAS
WARNING
CAUTION:
23 Nm (2.3 m
kg, 17 ft
lb)
NOTE:
Always use new copper washer.
Allow the damper rod assembly to slide
slowly down the inner tube
1 until it pro-
trudes from the bottom of the inner tube. Be
careful not to damage the inner tube.
2. Lubricate:

inner tube’s outer surface
Recommended lubricant
Suspension oil “01” or
equivalent
3. Tighten:

damper rod assembly bolt
1
LOCTITE
While holding the damper rod assembly with the
damper rod holder
2, tighten the damper rod
assembly bolt.
Damper rod holder
90890-01423, YM-01423
4. Install:

dust seal
1

oil seal clip 2

oil seal 3

washer 4
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4-52
FRONT FORKCHAS
CAUTION:
NOTE:
NOTE:
Make sure the numbered side of the oil seal
faces up.

Before installing the oil seal, lubricate its lips
with lithium-soap-based grease.

Lubricate the outer surface of the inner tube
with fork oil.

Before installing the oil seal, cover the top of
the front fork leg with a plastic bag to protect
the oil seal during installation.
5. Install :

Oil seal
1
(with the fork seal driver 2)
Fork seal driver
90890-01442, YM-01442
6. Install:

oil seal clip
1
Adjust the oil seal clip so that it fits into the outer
tube’s groove.
7. Install:

dust seal
1
(with the fork seal driver weight 2)
Fork seal driver
90890-01442m YM-01442
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4-53
FRONT FORKCHAS
NOTE:
NOTE: 8. Install:

rod puller
1

rod puller attachment 2
(onto the damper rod 3)
Rod puller
90890-01437, YM-01437
Rod puller attachment
90890-01436, YM-01436
9. Fill:

front fork leg
(with the specified amount of the recom-
mended fork oil)
Quantity (each front fork leg)
0.53 L (0.47 Imp qt, 0.56 US qt)
Recommended oil
Suspension oil “01” or
equivalent
Front fork leg oil level (from the
top of the outer tube, with the
outer tube fully compressed and
without the fork spring)
76 mm (2.99 in)

While filling the front fork leg, keep it upright.

After filling, slowly pump the front fork leg up
and down to distribute the fork oil.
10. Install:

nut
1

fork spring 2

spacer 3

damper adjusting rod 4

cap bolt 5
a. Remove the rod puller and adapter.
b. Install the nut.
c. Install the fork spring, and spacer.
Install the spring with the smaller pitch
a facing
up
A.
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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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4-65
Order Job / Part Q’ty Remarks
1
2
3
4
5
6
7
8
9
10Removing the rear shock absorber
assembly
EXUP servo motor
Self-locking nut / bolt
Self-locking nut / bolt
Self-locking nut / bolt
Self-locking nut
Rear shock absorber assembly
Oil seal / bearing / collar
Collar / self-locking nut / bolt
Connecting arm
Oil seal / bearing / collar
Relay arm1/1
1/1
1/1
1
1
6/3/3
1/1/1
2
2/1/1
1Remove the parts in the order listed.
Refer to “EXHAUST PIPE” in chapter 5.
For installation, reverse the removal
procedure.
92 Nm (9.2 m
kg, 67 ft
lb)44 Nm (4.4 m
kg, 32 ft
lb)
44 Nm (4.4 m
kg, 32 ft
lb)44 Nm (4.4 m
kg, 32 ft
lb)
REAR SHOCK ABSORBER ASSEMBLYCHAS
EAS00685
REAR SHOCK ABSORBER ASSEMBLY
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4-68
REAR SHOCK ABSORBER ASSEMBLYCHAS
NOTE:
44 Nm (4.4 m
kg, 32 ft
lb)
44 Nm (4.4 m
kg, 32 ft
lb)
44 Nm (4.4 m
kg, 32 ft
lb)
EAS00695
CHECKING THE REAR SHOCK ABSORBER
ASSEMBLY
1. Check:

rear shock absorber rod
Bends / damage
Replace the rear shock
absorber assembly.

rear shock absorber
Gas leaks / oil leaks
Replace the rear
shock absorber assembly.

spring
Damage / wear
Replace the rear shock ab-
sorber assembly.

bushings
Damage / wear
Replace.

dust seals
Damage / wear
Replace.

bolts
Bends / damage / wear
Replace.
EAS00698
INSTALLING THE REAR SHOCK
ABSORBER ASSEMBLY
1. Lubricate:

spacers

bearings
Recommended lubricant
Lithium – soap-based grease
2. Install:

rear shock absorber assembly

When installing the rear shock absorber as-
sembly, lift up the swingarm.

Install the connecting arm front bolt from the
right.
3. Tighten:

rear shock absorber assembly upper nut

rear shock absorber assembly lower nut

relay arm-to swingarm nut
4. Install :

EXUP servo motor
Refer to “EXHAUST PIPE” in chapter 5.

bottom cowling
Refer to “COWLINGS” in chapter 3.
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4-73
SWINGARM AND DRIVE CHAINCHAS
NOTE: 3. Wash:

pivot shaft

dust covers

spacer

washers

bearings
Recommended cleaning solvent
Kerosene
4. Check:

dust covers
1

spacer 2
Damage / wear
Replace.

bearings
3
Damage / pitting
Replace.
5. Check:

connecting arms
1

relay arm 2
Damage / wear
Replace.
6. Check:

bearings
3

oil seals 4
Damage / pitting
Replace.
7. Check:

collars
5
Damage / scratches
Replace.
EAS00709
CHECKING THE DRIVE CHAIN
1. Measure:

ten-link section
a of the drive chain
Out of specification
Replace the drive
chain.
Ten-link drive chain section limit
(maximum)
150.1 mm (5.91 in)

While measuring the ten-link section, push
down on the drive chain to increase its tension.

Measure the length between drive chain roller
1 and 11 as shown.

Perform this measurement at two or three dif-
ferent places.
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4-74
SWINGARM AND DRIVE CHAINCHAS
CAUTION:
2. Check:

drive chain
Stiffness
Clean and lubricate or replace.
3. Clean:

drive chain
a. Wipe the drive chain with a clean cloth.
b. Put the drive chain in kerosene and remove
any remaining dirt.
c. Remove the drive chain from the kerosene
and completely dry it.
This motorcycle has a drive chain with small
rubber O-rings
1 between the drive chain
side plates. Never use high-pressure water
or air, steam, gasoline, certain solvents
(e.g., benzine), or a coarse brush to clean the
drive chain. High-pressure methods could
force dirt or water into the drive chain’s in-
ternals, and solvents will deteriorate the O-
rings. A coarse brush can also damage the
O-rings. Therefore, use only kerosene to
clean the drive chain. Don’t soak drive chain
in kerosine more them ten minutes. O-ring is
damage by kerosine.
4. Check:

O-rings
1
Damage
Replace the drive chain.

drive chain rollers
2
Damage / wear
Replace the drive chain.

drive chain side plates
3
Damage / wear
Replace the drive chain.
Cracks
Replace the drive chain and make
sure the battery breather hose is properly
routed away from the drive chain and below
the swingarm.
5. Lubricate:

drive chain
Recommended lubricant
Engine oil or chain lubricant
suitable for O-ring chains
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5-5
Order Job / Part Q’ty Remarks
1
2Disconnecting the leads and hoses
Fuel tank
Air filter case
Throttle body assembly
Engine oil
Oil cooler
Air cut-off valve
Starter motor
Battery negative lead
Battery positive lead1
1Disconnect the parts in the order listed.
Refer to “FUEL TANK” in chapter 3.
Refer to “AIR FILTER CASE” in chapter 3.
Refer to “THROTTLE BODIES” in
chapter 7.
Drain.
Refer to “CHANGING THE ENGINE OIL”
in chapter 3.
Refer to “OIL COOLER” in chapter 6.
Refer to “AIR INDUCTION SYSTEM” in
chapter 7.
Refer to “STARTING SYSTEM” in
chapter 7.
ENGINEENG
LEADS AND HOSES
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5-6
Order Job / Part Q’ty Remarks
3
4
5
6
7
8
9
10Clutch cable
Ground lead
Stator coil assembly coupler
Crankshaft position sensor lead coupler
Oil level switch connector
Neutral switch connector
Speed sensor coupler
Cylinder identification sensor coupler1
2
1
1
1
1
1
1First, disconnect the negative battery
lead, and then the positive battery lead.
For connecting, reverse the disconnec-
tion procedure.
Disconnect.
Disconnect.
Disconnect.
Disconnect.
Disconnect.
Disconnect.
For installation, reverse the removal
procedure.
CAUTION:
ENGINEENG
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