oil YAMAHA YZF-R1S 2004 Owners Manual

5-33
VALVES AND VALVE SPRINGSENG
NOTE:
NOTE:
NOTE:
2. Lubricate:

valve stem
1

valve stem seal 2
(with the recommended lubricant)
Recommended lubricant
Molybdenum disulfide oil
3. Install:

valve
1

lower spring seat 2

valve stem seal 3

valve spring 4

upper spring seat 5
(into the cylinder head)
Install the valve spring with the larger pitch
a
facing up.
bSmaller pitch
Make sure that each valve is installed in its origi-
nal place. Refer to the following embossed
marks.
Right and left intake valve(-s): “5VY :”
Middle intake valve(-s): “5VY
.”
Exhaust valve(-s): “5VY”
4. Install:

valve cotters
1
Install the valve cotters by compressing the
valve spring with the valve spring compressor
2 and the valve spring compressor attachment
3.
Valve spring compressor
90890-04019, YM-04019
Valve spring compressor
attachment
Intake valve
90890-04114, YM-4114
Exhaust valve
90890-04108, YM-4108
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5-34
VALVES AND VALVE SPRINGSENG
CAUTION:
NOTE: 5. To secure the valve cotters onto the valve
stem, lightly tap the valve tip with a soft-face
hammer.
Hitting the valve tip with excessive force
could damage the valve.
6. Install:

valve pad
1

valve lifter 2

Lubricate the valve lifter and valve pad with
molybdenum disulfide oil.

The valve lifter must move smoothly when ro-
tated with a finger.

Each valve lifter and valve pad must be rein-
stalled in its original position.
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5-35
Order Job / Part Q’ty Remarks
1
2
3
4
5
6
7
8
9Removing the stator coil assembly
Rider seat
Fuel tank
Left side cowling
Bottom cowlings
Engine oil
Stator coil assembly lead coupler
Plug
Generator rotor cover
Gasket
Dowel pin
Generator rotor assembly
Dowel pin
Bearing housing
Collar1
1
1
1
2
1
2
1
1Remove the parts in the order listed.
Refer to “SEATS” in chapter 3.
Refer to “FUEL TANK” in chapter 3.
Refer to “COWLINGS” in chapter 3.
Drain.
Refer to “CHANGING THE ENGINE OIL”
in chapter 3.
Disconnect.
10 Nm (1.0 m
kg, 7.2 ft
lb)
12 Nm (1.2 m
kg, 8.7 ft
lb)
12 Nm (1.2 m
kg, 8.7 ft
lb)
12 Nm (1.2 m
kg, 8.7 ft
lb)
10 Nm (1.0 m
kg, 7.2 ft
lb)
10 Nm (1.0 m
kg, 7.2 ft
lb)
14 Nm (1.4 m
kg, 10 ft
lb)
22 Nm (2.2 m
kg, 16 ft
lb)
22 Nm (2.2 m
kg, 16 ft
lb)
STARTER CLUTCH AND GENERATORENG
STARTER CLUTCH AND GENERATOR
STATOR COIL ASSEMBLY
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5-36
STARTER CLUTCH AND GENERATORENG
Order Job / Part Q’ty Remarks
10
11
12
13
14
15Bearing
Stator coil assembly lead holder
Idler gear
Idler gear shaft
Washer
Bearing1
1
1
1
1
1
For installation, reverse the removal
procedure.
10 Nm (1.0 m
kg, 7.2 ft
lb)
12 Nm (1.2 m
kg, 8.7 ft
lb)
12 Nm (1.2 m
kg, 8.7 ft
lb)
12 Nm (1.2 m
kg, 8.7 ft
lb)
10 Nm (1.0 m
kg, 7.2 ft
lb)
10 Nm (1.0 m
kg, 7.2 ft
lb)
14 Nm (1.4 m
kg, 10 ft
lb)
22 Nm (2.2 m
kg, 16 ft
lb)
22 Nm (2.2 m
kg, 16 ft
lb)
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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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5-41
STARTER CLUTCH AND GENERATORENG
NOTE:
NOTE:
10 Nm (1.0 m
kg, 7.2 ft
lb)
INSTALLING THE STARTER CLUTCH
1. Install:

generator rotor
1

damper 2

driven gear 3

The hole side of the damper is installed to the
generator side.

Lubricate the engine oil
4.
2. Install:

starter clutch drive gear
1

collar 2

washer 3
Refer to “CHECKING THE STARTER
CLUTCH”.
3. Install:

washer
1

O-ring 2 New

spacer
3
Lubricate the engine oil to O-ring.
INSTALLING THE GENERATOR
1. Install:

idle gear shaft

idle gear
1

washer

idle gear shaft bolt
2
LOCTITE
2. Install:

generator rotor and starter clutch assembly
1
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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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5-43
Order Job / Part Q’ty Remarks
1
2
3
4
5
6Removing the crankshaft position
sensor
Rider seat
Fuel tank
Side cowlings
Bottom cowlings
Engine oil
Crankshaft position sensor lead coupler
Crankshaft position sensor
O-ring
Pickup rotor cover
Gasket
Cover1
1
1
1
1
1Remove the parts in the order listed.
Refer to “SEATS” in chapter 3.
Refer to “FUEL TANK” in chapter 3.
Refer to “COWLINGS” in chapter 3.
Drain.
Refer to “CHANGING THE ENGINE OIL”
in chapter 3.
Disconnect.
For installation, reverse the removal
procedure.
10 Nm (1.0 m
kg, 7.2 ft
lb)
12 Nm (1.2 m
kg, 8.7 ft
lb)
12 Nm (1.2 m
kg, 8.7 ft
lb)
12 Nm (1.2 m
kg, 8.7 ft
lb)
CRANKSHAFT POSITION SENSORENG
CRANKSHAFT POSITION SENSOR
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5-44
CRANKSHAFT POSITION SENSORENG
NOTE:
12 Nm (1.2 m
kg, 8.7 ft
lb)
10 Nm (1.0 m
kg, 7.2 ft
lb)
REMOVING THE CRANKSHAFT POSITION
SENSOR
1. Remove:

rider seat

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

right side cowling

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

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

crankshaft position sensor lead coupler
5. Remove:

crankshaft position sensor

O-ring

pickup rotor cover
1
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.
INSTALLING THE CRANKSHAFT POSITION
SENSOR
1. Install:

gasket
New

pickup rotor cover
1

O-ring New

crankshaft position sensor
LOCTITE
2. Connect:

crankshaft position sensor lead coupler
3. Fill:

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

right side cowling

bottom cowlings
Refer to “COWLINGS” in chapter 3.
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5-46
Order Job / Part Q’ty Remarks
1
2
3
4
5
6Removing the clutch cover
Right side cowling
Bottom cowling
Engine oil
Cover
Clutch cable
Clutch cover
Clutch cover gasket
Dowel pin
Oil filler cap1
1
1
1
2
1Remove the parts in the order listed.
Drain.
Refer to “CHANGING THE ENGINE OIL”
in chapter 3.
Disconnect.
For installation, reverse the removal
procedure.
Refer to “COWLINGS” in chapter 3.
12 Nm (1.2 m
kg, 8.7 ft
lb)
12 Nm (1.2 m
kg, 8.7 ft
lb)
10 Nm (1.0 m
kg, 7.2 ft
lb)
CLUTCHENG
CLUTCH
CLUTCH COVER
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