bolt pattern YAMAHA YZF-R1S 2004 Service Manual

2-18
EAS00030
GENERAL TIGHTENING TORQUE
SPECIFICATIONS
This chart specifies tightening torques for stan-
dard fasteners with a standard ISO thread
pitch. Tightening torque specifications for spe-
cial components or assemblies are provided
for each chapter of this manual. To avoid war-
page, tighten multi-fastener assemblies in a
crisscross pattern and progressive stages until
the specified tightening torque is reached. Un-
less otherwise specified, tightening torque
specifications require clean, dry threads. Com-
ponents should be at room temperature.
A: Distance between flats
B: Outside thread diameter
A
(nut)B
(bolt)General tightening
torques
10 mm
12 mm
14 mm
17 mm
19 mm
22 mm6 mm
8 mm
10 mm
12 mm
14 mm
16 mmNm m
kg
6
15
30
55
85
1300.6
1.5
3.0
5.5
8.5
13.0
ft
lb
4.3
11
22
40
61
94
CONVERSION TABLE /
GENERAL TIGHTENING TORQUE SPECIFICATIONS
SPEC
EAS00028
CONVERSION TABLE
All specification data in this manual are listed in
SI and METRIC UNITS.
Use this table to convert METRIC unit data to
IMPERIAL unit data.
Ex.
METRIC MULTIPLIER IMPERIAL
** mm

0.03937 = ** in
2 mm

0.03937 = 0.08 in
CONVERSION TABLE
METRIC TO IMPERIAL
Metric unitMultiplierImperial unit
Tighten-
ing
torquem
kg
m
kg
cm
kg
cm
kg7.233
86.794
0.0723
0.8679ft
lb
in
lb
ft
lb
in
lb
Weightkg
g2.205
0.03527lb
oz
Speedkm / hr0.6214mph
Distance
km
m
m
cm
mm0.6214
3.281
1.094
0.3937
0.03937mi
ft
yd
in
in
Volume /
Capacity
cc (cm3)
cc (cm3)
lt (liter)
lt (liter)0.03527
0.06102
0.8799
0.2199oz (IMP liq.)
cu
in
qt (IMP liq.)
gal (IMP liq.)
Misc.
kg / mm
kg / cm2
Centigrade
(C)
55.997
14.2234
9 / 5+32lb / in
psi (lb / in2)
Fahrenheit
(F)
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3-6
FUEL TANK
CHK
ADJ
4 Nm (0.4 m
kg, 2.9 ft
lb)
NOTE:
CAUTION:
INSTALLING THE FUEL PUMP
1. Install:

fuel pump

Do not damage the installation surfaces of the
fuel tank when installing the fuel pump.

Always use a new fuel pump gasket.

Install the fuel pump as shown in the illustra-
tion.

Tighten the fuel pump bolts in stages in a criss-
cross pattern and to the specified torque.
INSTALLING THE FUEL TANK
1. Install:

fuel hose

fuel return hose

fuel hose connector cover
When installing the fuel hose, make sure
that it is securely connected, and that the
fuel hose holder is in the correct position,
otherwise the fuel hose will not be properly
installed.
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4-5
FRONT WHEEL AND BRAKE DISCSCHAS
NOTE:
EAS00533
CHECKING THE BRAKE DISCS
The following procedure applies to all of the
brake discs.
1. Check:

brake disc
Damage / galling
Replace.
2. Measure:

brake disc deflection
Out of specification
Correct the brake disc
deflection or replace the brake disc.
Brake disc deflection limit
(maximum)
Front : 0.1 mm (0.004 in)
Rear : 0.15 mm (0.006 in)
a. Place the motorcycle on a suitable stand so
that the wheel is elevated.
b. Before measuring the front brake disc deflec-
tion, turn the handlebars to the left or right to
ensure that the front wheel is stationary.
c. Remove the brake caliper.
d. Hold the dial gauge at a right angle against
the brake disc surface.
e. Measure the deflection 1.5 mm (0.06 in) be-
low the edge of the brake disc.
3. Measure:

brake disc thickness
Measure the brake disc thickness at a few
different locations.
Out of specification
Replace.
Brake disc thickness limit
(minimum)
Front : 4.0 mm (0.16 in)
Rear : 4.5 mm (0.18 in)
4. Adjust:

brake disc deflection
a. Remove the brake disc.
b. Rotate the brake disc by one bolt hole.
c. Install the brake disc.
Tighten the brake disc bolts in stages and in a
crisscross pattern.
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4-14
REAR WHEEL AND BRAKE DISCCHAS
NOTE:
150 Nm (15 m
kg, 108 ft
lb)
27 Nm (2.7 m
kg, 20 ft
lb)
22 Nm (2.2 m
kg, 16 ft
lb)
NOTE: 2. Replace:

rear wheel sprocket
a. Remove the self-locking nuts and the rear
wheel sprocket.
b. Clean the rear wheel drive hub with a clean
cloth, especially the surfaces that contact the
sprocket.
c. Install the new rear wheel sprocket.
Rear wheel sprocket self-locking
nut
100 Nm (10 m
kg, 72 ft
lb)
Tighten the self-locking nuts in stages and in a
crisscross pattern.
EAS00572
INSTALLING THE REAR WHEEL
1. Lubricate:

wheel axle

wheel bearings

oil seal lips
Recommended lubricant
Lithium-soap-based grease
2. Tighten:

wheel axle nut

brake caliper bolts (front)
(rear)
EAS00575
ADJUSTING THE REAR WHEEL STATIC
BALANCE

After replacing the tire, wheel or both, the rear
wheel static balance should be adjusted.

Adjust the rear wheel static balance with the
brake disc and rear wheel drive hub installed.
1. Adjust:

rear wheel static balance
Refer to “ADJUSTING THE FRONT WHEEL
STATIC BALANCE”.
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5-14
CAMSHAFTENG
NOTE:
CAUTION:
EAS00198
REMOVING THE CAMSHAFTS
1. Remove:

pickup rotor cover
Refer to “CRANKSHAFT POSITION SEN-
SOR AND PICKUP ROTOR”.
2. Align:

“T” mark
a on the pickup rotor
(with the crankcase mating surface
b)
a. Turn the crankshaft clockwise.
b. When piston #1 is at TDC on the compres-
sion stroke, align the “T” mark
a on the pick-
up rotor with the crankcase mating surface
b.
TDC on the compression stroke can be found
when the camshaft lobes are turned away from
each other.
3. Loosen:

camshaft sprocket bolts
1
Camshaft wrench
90890-04143
4. Remove:

timing chain tensioner
1

O-ring
5. Remove:

camshaft caps
1

dowel pins
To prevent damage to the cylinder head,
camshafts or camshaft caps, loosen the
camshaft cap bolts in stages and in a criss-
cross pattern, working from the outside in.
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5-16
CAMSHAFTENG
NOTE:
3. Measure:

camshaft runout
Out of specification
Replace.
Camshaft runout limit
0.03 mm (0.0012 in)
4. Measure:

camshaft-journal-to-camshaft-cap clear-
ance
Out of specification
Measure the camshaft
journal diameter.
Camshaft-journal-to-camshaft-
cap clearance
0.028
0.062 mm
(0.0011
0.0024 in)
a. Install the camshaft into the cylinder head
(without the dowel pins and camshaft caps).
b. Position strip of Plastigauge
 1 onto the
camshaft journal as shown.
c. Install the dowel pins and camshaft caps.

Tighten the camshaft cap bolts in stages and in
a crisscross pattern, working from the inner
caps out.

Do not turn the camshaft when measuring the
camshaft journal-to-camshaft cap clearance
with the Plastigauge
.
Camshaft cap bolt
10 Nm (1.0 m
kg, 7.2 ft
lb)
d. Remove the camshaft caps and then mea-
sure the width of the Plastigauge
 1.
5. Measure:

camshaft journal diameter
a
Out of specification
Replace the cam-
shaft.
Within specification
Replace the cylinder
head and the camshaft caps as a set.
Camshaft journal diameter
22.459
22.472 mm
(0.8842
0.8847 in)
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5-20
CAMSHAFTENG
10 Nm (1.0 m
kg, 7.2 ft
lb)
NOTE:
CAUTION:
24 Nm (2.4 m
kg, 17 ft
lb)
CAUTION:
5. Install:

camshaft cap bolts
Tighten the camshaft cap bolts in stages and in
a crisscross pattern, working from the inner
caps out.

Lubricate the camshaft cap bolts with the
engine oil.

The camshaft cap bolts must be tightened
evenly or damage to the cylinder head,
camshaft caps, and camshafts will result.

Do not turn the crankshaft when installing
the camshaft to avoid damage or improper
valve timing.
6. Tighten:

camshaft sprocket bolts
1
Camshaft wrench
90890-04143
Be sure to tighten the camshaft sprocket
bolts to the specified torque to avoid the
possibility of the bolts coming loose and
damaging the engine.
7. Align:

camshaft punch mark
a
Align the camshaft punch mark a and the
camshaft cap arrow mark
b.
Camshaft wrench
90890-04143
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5-23
CYLINDER HEADENG
NOTE:
NOTE:
NOTE:
EAS00222
REMOVING THE CYLINDER HEAD
1. Remove:

intake camshaft

exhaust camshaft
Refer to “REMOVING THE CAMSHAFTS”.
2. Remove:

cylinder head nuts

cylinder head bolts

Loosen the nuts in the proper sequence as
shown.

Loosen each nut 1 / 2 of a turn at a time. After all
of the nuts are fully loosened, remove them.
EAS00227
CHECKING THE CYLINDER HEAD
1. Eliminate:

combustion chamber carbon deposits
(with a rounded scraper)
Do not use a sharp instrument to avoid damag-
ing or scratching:

spark plug bore threads

valve seats
2. Check:

cylinder head
Damage / scratches
Replace.
3. Measure:

cylinder head warpage
Out of specification
Resurface the cylin-
der head.
Maximum cylinder head warpage
0.10 mm (0.0039 in)
a. Place a straightedge
1 and a thickness
gauge
2 across the cylinder head.
b. Measure the warpage.
c. If the limit is exceeded, resurface the cylinder
head as follows.
d. Place a 400
600 grit wet sandpaper on the
surface plate and resurface the cylinder
head using a figure-eight sanding pattern.
To ensure an even surface, rotate the cylinder
head several times.
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5-38
STARTER CLUTCH AND GENERATORENG
NOTE: REMOVING THE GENERATOR
1. Remove:

rider seat

fuel tank
Refer to “SEATS” and “FUEL TANK” in chapter
3.
2. Remove:

left side cowling

bottom cowlings
Refer to “COWLINGS” in chapter 3.
3. Drain:

engine oil
Refer to “CHANGING THE ENGINE OIL” in
chapter 3.
4. Remove:

plug

generator rotor cover
1

While pushing generator rotor, remove the
generator rotor cover.

Loosen each bolt 1 / 4 of a turn a time, in stages
and in a crisscross pattern.

After all of the bolts are fully loosened, remove
them.
5. Remove:

generator rotor and starter clutch assembly
1.
6. Remove:

idler gear shaft bolt
1

idler shaft

idler gear
2
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5-42
STARTER CLUTCH AND GENERATORENG
12 Nm (1.2 m
kg, 8.7 ft
lb)
22 Nm (2.2 m
kg, 16 ft
lb)
NOTE: 3. Install:

generator cover gasket

generator cover
1
(M6 bolts)
(M8 bolts)

First tighten the M8 bolts and then tighten the
M6 bolts.

Tighten the generator rotor cover bolts in
stages and in a crisscross pattern.
4. Fill:

engine oil
Refer to “CHANGING THE ENGINE OIL” in
chapter 3.
5. Install:

bottom cowling

left side cowling
Refer to “COWLINGS” in chapter 3.
6. Install:

fuel tank

rider seat
Refer to “SEATS” and “FUEL TANK” in chap-
ter 3.
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