oil YAMAHA YZF-R1S 2004 Owner's Manual

2-19
TIGHTENING TORQUESSPEC
Use a lock
washer
TIGHTENING TORQUES
ENGINE TIGHTENING TORQUES
ItemFastenerThreadQ’tyTightening torqueRemarksItemFastenersizeQtyNmm
kgft
lbRemarks
Spark plugs—M104131.39.4
Cylinder headNutM1010See NOTE 1
BoltM62121.28.7
Camshaft capsBoltM628101.07.2
Cylinder head coverBoltM66121.28.7
Cylinder head (exhaust pipe)Stud boltM88151.511
Air indication system capBoltM64101.07.2
Camshaft sprocketsBoltM74242.417
Cylinder head and throttle bodyClampM5430.32.2
Connecting rod capsBoltM8820+1502.0+15014+150
Generator rotorBoltM101606.043
Timing chain tensionerBoltM62101.07.2
Water pump outlet pipeBoltM61101.07.2
Water pump inlet pipeBoltM61101.07.2
(water pump side)
Water pump inlet pipe (front side)BoltM61101.07.2
Oil / water pump assembly
sprocketBoltM61151.511
Water pumpBoltM62121.28.7
Thermostat coverNutM62101.07.2
Thermostat inlet pipeBoltM61101.07.2
Oil coolerBoltM201636.346
Engine oil drain boltBoltM141434.331
Oil pipeBoltM62101.07.2
Oil strainerBoltM63101.07.2
Oil delivery pipeBoltM63101.07.2
Oil filter union boltBoltM201707.051
Oil filter—M201171.712
Oil panBoltM614121.28.7
Oil panBoltM61121.28.7
Air filter case coverScrewM5101.70.171.2
Throttle body and throttle body
jointClampM5430.32.2
Throttle body and funnelBoltM564.20.423.0
Throttle cableNutM614.50.453.3
Throttle cable adjusterBoltM614.50.453.3
Stator coilScrewM63141.410
Generator rotor cover and
bearing housingScrewM63101.07.2
Pull lever coverBoltM62101.07.2
Thermostat assembly stayBoltM62101.07.2
Starter clutch idler gearBoltM61101.07.2
Clutch bossNutM201959.569Stake
Clutch springBoltM66101.07.2
Drive sprocketNutM221858.561
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2-20
TIGHTENING TORQUESSPEC
ItemFastenerThreadQ’tyTightening torqueRemarksItemFastenersizeQtyNmm
kgft
lbRemarks
Exhaust pipe and cylinder headNutM88202.014
Catalyst pipe assembly and
mufflerBoltM82202.014
Exhaust pipe and exhaust valveBoltM65101.07.2
pipe assembly
Exhaust valve pipe and housingBoltM61101.07.2
Pulley and shaft armNutM6170.75.0
EXUP pulley bracketBoltM61101.07.2
EXUP pulley coverBoltM62101.07.2
Exhaust valve pipe and bracketBoltM81202.014
EXUP cable nutNutM6270.75.0
Catalyst pipe bracket and frameBoltM81202.014
Catalyst pipe and catalyst pipeBoltM81202.014
bracket
Exhaust valve pipe and catalyst
pipeBoltM81202.014
EXUP servo motorBoltM6270.75.0
Muffler and rear frameBoltM82232.317
Muffler coverBoltM62101.07.2
CrankcaseStud boltM101080.85.8
Crankcase (main journal)BoltM910See NOTE 2
CrankcaseBoltM610121.28.7
CrankcaseBoltM81242.417
CrankcaseBoltM85242.417
Generator rotor coverBoltM64121.28.7
Generator rotor coverBoltM83222.216
Drive sprocket coverBoltM62101.07.2
Drive sprocket coverBoltM61101.07.2
Crankcase cover (left)ScrewM63101.07.2
Clutch coverBoltM67121.28.7
Clutch coverBoltM61121.28.7
Pickup rotor coverBoltM66121.28.7
Breather coverBoltM64121.28.7
Breather plateBoltM63101.07.2
PlateBoltM62101.07.2
Pickup rotor cover blind boltBoltM81151.511
Generator rotor cover plugPlugM20180.85.8
Main gallery plug (oil return)PlugM16380.85.8
Main gallery plugPlugM20180.85.8
Oil return pipeBoltM62101.07.2
Oil return plugScrewM122242.417
Stator coil leadBoltM61101.07.2
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2-21
TIGHTENING TORQUESSPEC
NOTE 1:
NOTE 2:
ItemFastenerThreadQ’tyTightening torqueRemarksItemFastenersizeQtyNmm
kgft
lbRemarks
Main axle bearing housingBoltM63121.28.7
Shift fork shaft stopperBoltM62101.07.2
Stopper screwScrewM81222.216
Shift rod lock nut (rear)NutM6170.75.0Left thread
Shift rod lock nut (front)NutM6170.75.0
Shift rod jointBoltM61101.07.2
Shift armBoltM61101.07.2
E.C.U.ScrewM6270.75.0
Neutral switch—M101202.015
EXUP servo motor coverScrewM5220.21.5
Coolant temperature sensor—M121181.813
Cylinder identification sensorBoltM6180.85.7
Atmospheric pressure sensorScrewM5270.75.0
Crankshaft position sensorBoltM61101.07.2
Oil level switchBoltM62101.07.2
1. First, tighten the bolts to approximately 19 Nm (1.9 m
kg, 14 ft
lb) with a torque wrench following the
tightening order.
2. Retighten the bolts 67 Nm (6.7 m
kg, 48 ft
lb) with a torque wrench.
1. First, tighten the bolts to approximately 20 Nm (2.0 m
kg, 15 ft
lb) with a torque wrench following the
tightening order.
2. Loosen the all bolts one by one following the tightening order and then tighten them to 20 Nm (2.7
m
kg, 15 ft
lb) again.
3. Retighten the bolts further to reach the specified angle (60).
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2-25
LUBRICATION POINTS AND LUBRICANT TYPESSPEC
EAS00031
LUBRICATION POINTS AND LUBRICANT TYPES
ENGINE
Lubrication point
Lubricant
Oil seal lips
O-rings
Bearings
Crankshaft pins
Piston surfaces
Piston pins
Crankshaft journals
Camshaft lobes
Camshaft journals
Valve stems (intake and exhaust)
Valve stem ends (intake and exhaust)
Water pump impeller shaft
Oil pump rotors (inner and outer)
Oil pump housing
Oil strainer
Clutch (pull rod)
Oil / water pump drive sprocket and washer
Clutch (thrust plate)
Starter clutch idle gear inner surface
Starter clutch assembly
Primary driven gear
Transmission gears (wheel and pinion)
Main axle and drive axle
Shift drum
Shift forks and shift fork guide bars
Shift shaft
Shift shaft boss
Cylinder head cover mating surfaceYamaha bond
No.1215
Crankcase mating surfaceYamaha bond
No.1215
Clutch cover (crankcase mating surface)Yamaha bond
No.1215
Generator rotor cover (crankcase mating surface)Yamaha bond
No.1215
Pickup rotor coverYamaha bond
No.1215
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2-26
LUBRICATION POINTS AND LUBRICANT TYPESSPEC
EAS00032
CHASSIS
Lubrication point
Lubricant
Steering bearings and bearing races (upper and lower)
Throttle grip inner surface
Brake lever pivoting point and metal-to-metal moving parts
Clutch lever pivoting point and metal-to-metal moving parts
Engine mount bolts (rear upper and lower)
Relay arm, connecting rod and rear shock absorber collar
Pivot shaft
Swingarm pivot bearing
Swingarm head pipe end, oil seal and bush
Oil seal (relay arm, connecting arm and rear shock absorber)
Seat lock assembly moving parts
Sidestand pivoting pint and metal-to-metal moving parts
Link and sidestand switch contact point
Sidestand hook and spring
Shift shaft joint
Front wheel oil seal (right and left)
Front axle shaft
Rear wheel oil seal
Rear wheel drive hub oil seal
Rear wheel drive hub mating surface
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2-28
1Thermostat
2Radiator cap
3Radiator
4Oil cooler
COOLING SYSTEM DIAGRAMSSPEC
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2-29
ENGINE OIL LUBRICATION CHARTSPEC
ENGINE OIL LUBRICATION CHART
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2-30
LUBRICATION DIAGRAMSSPEC
1Intake camshaft
2Exhaust camshaft
3Oil filter cartridge
4Oil level switch
EAS00034
LUBRICATION DIAGRAMS
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2-31
1Intake camshaft
2Exhaust camshaft
3Crankshaft
4Oil cooler
5Oil pipe
6Oil strainer
7Oil pump
8Relief valve
LUBRICATION DIAGRAMSSPEC
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2-32
1Oil cooler
2Oil filter cartridge
3Oil level switch
4Oil strainer
5Oil pump
6Oil pipe
LUBRICATION DIAGRAMSSPEC
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