clutch YAMAHA YZF-R1S 2004 Workshop Manual

5-57
CLUTCHENG
NOTE:
12 Nm (1.2 m
kg, 8.7 ft
lb)
12 Nm (1.2 m
kg, 8.7 ft
lb)
NOTE: 11. Install:

clutch cover

clutch cover gasket
New

Install the pull rod so that the teeth a face to-
wards the rear of the motorcycle. Then, install
the clutch cover.

Apply oil onto the bearing.

Apply molybdenum disulfide grease onto the
pull rod.

When installing the clutch cover, push the pull
lever and check that the punch mark
a on the
pull lever aligns with the mark
b on the clutch
cover. Make sure that the pull rod teeth and
pull lever shaft pinion gear are engaged.

Tighten the clutch cover bolts in stages and in
a crisscross pattern.
12. Tighten:

clutch cover bolts
1

clutch cover bolt 2
LOCTITE
Tighten the clutch cover bolts in a stages and in
a crisscross pattern.
13. Adjust:

clutch cable free play
Refer to “ADJUSTING THE CLUTCH
CABLE FREE PLAY” in chapter 3.
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5-58
Order Job / Part Q’ty Remarks
1
2
3
4
5
6
7
8
9Removing the shift shaft and stopper
lever
Side cowlings
Bottom cowlings
Clutch assembly
Sift arm and shift rod
Circlip
Washer
Shift shaft
Collar
Shift shaft spring
Washer
Stopper screw
Stopper lever
Washer1
1
1
1
1
1
1
1
1Remove the parts in the order listed.
Refer to “CLUTCH”.
Refer to “ENGINE”.
Refer to “COWLINGS” in chapter 3.
22 Nm (2.2 m
kg, 16 ft
lb)
SHIFT SHAFTENG
EAS00327
SHIFT SHAFT
SHIFT SHAFT AND STOPPER LEVER
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5-60
SHIFT SHAFTENG
REMOVING THE SHIFT SHAFT
1. Remove:

left and right side cowlings

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

clutch assembly
Refer to “CLUTCH”.
3. Remove:

shift arm

shift rod
Refer to “ENGINE”.
4. Remove:

circlip
1

Washer 2
(left side of the engine)
5. Remove:

shift shaft
1

shift shaft spring 2

collar

washer
6. Remove:

stopper lever spring
1

stopper screw 2

stopper lever 3

washer
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5-62
SHIFT SHAFTENG
4. Install:

shift rod

shift arm
Refer to “ENGINE”.
5. Install:

clutch assembly
Refer to “CLUTCH”.
6. Install:

left and side cowling

bottom cowlings
Refer to “COWLING” in chapter 3.
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5-63
Order Job / Part Q’ty Remarks
1
2
3
4
5
6
7
8Removing the oil pan and oil pump
Side cowlings
Bottom cowlings
Engine oil
Exhaust pipe and exhaust valve pipe
Clutch assembly
Water pump inlet pipe
Water pump outlet pipe
Oil level switch lead coupler
Oil level switch
Oil level switch lead holder
Oil pan
Oil pan gasket
Dowel pin
Drain pipe
Oil strainer1
1
1
1
1
2
1
1Remove the parts in the order listed.
Drain.
Refer to “CHANGING THE ENGINE OIL”
in chapter 3.
Refer to “EXHAUST PIPE”.
Refer to “CLUTCH”.
Refer to “OIL COOLER” in chapter 6.
Disconnect.
Refer to “COWLINGS” in chapter 3.
10 Nm (1.0 m
kg, 7.2 ft
lb)
10 Nm (1.0 m
kg, 7.2 ft
lb)
10 Nm (1.0 m
kg, 7.2 ft
lb)10 Nm (1.0 m
kg, 7.2 ft
lb)
12 Nm (1.2 m
kg, 8.7 ft
lb)43 Nm (4.3 m
kg, 31 ft
lb)
12 Nm (1.2 m
kg, 8.7 ft
lb)
OIL PAN AND OIL PUMPENG
EAS00356
OIL PAN AND OIL PUMP
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5-72
Order Job / Part Q’ty Remarks
Removing the crankcase
Air filter case
Throttle body assembly
Engine
Cylinder head
Starter clutch and generator
Shift shaft
Crankshaft position sensor
Clutch
Oil pan and oil pump
Starter motorRemove the parts in the order listed.
Refer to “AIR FILTER CASE” in chapter 3.
Refer to “THROTTLE BODIES” in
chapter 7.
Refer to “ENGINE”.
Refer to “CYLINDER HEAD”.
Refer to “STARTER CLUTCH AND
GENERATOR”.
Refer to “SHIFT SHAFT”.
Refer to “CRANKSHAFT POSITION
SENSOR”.
Refer to “CLUTCH”.
Refer to “OIL PAN AND OIL PUMP”.
Refer to “STARTING SYSTEM” in
chapter 8.
12 Nm (1.2 m
kg, 8.7 ft
lb)12 Nm (1.2 m
kg, 8.7 ft
lb)
24 Nm (2.4 m
kg, 17 ft
lb)
10 Nm (1.0 m
kg, 7.2 ft
lb)
24 Nm (2.4 m
kg, 17 ft
lb)
12 Nm (1.2 m
kg, 8.7 ft
lb)
20 Nm (2.0 m
kg, 14 ft
lb) +60
CRANKCASEENG
CRANKCASE
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8-4
11Neutral switch
12Rear brake light switch
13Fuse box
1Main switch
2Horn switch
3Dimmer switch
4Turn signal switch
5Clutch switch
6Sidestand switch
7Engine stop switch
8Front brake light switch
9Start switch
10Oil level switch
CHECKING THE SWITCHESELEC
EAS00731
CHECKING THE SWITCHES
Check each switch for damage or wear, proper connections, and also for continuity between the termi-
nals. Refer to “CHECKING SWITCH CONTINUITY”.
Damage / wear
Repair or replace.
Improperly connected
Properly connect.
Incorrect continuity reading
Replace the switch.
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8-9
IGNITION SYSTEMELEC
1Main switch
4Fuse (main)
6Battery
10Starting circuit cut-off relay
11Neutral switch
12Sidestand switch
14E.C.U.
15Ignition coil #1
16Ignition coil #2
17Ignition coil #3
18Ignition coil #4
19Spark plug
31Crankshaft position sensor
35Cylinder identification sensor
36Lean angle cut-off switch
53Engine stop switch
59Clutch switch
73Fuse (ignition)
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8-10
YESNO 2. Battery

Check the condition of the battery.
Refer to “CHECKING AND CHARGING
THE BATTERY” in chapter 3.
Minimum open-circuit voltage
12.8 V or more at 20C (68F)

Is the battery OK?

Clean the battery
terminals.

Recharge or re-
place the battery.
EAS00739
YESNO
EAS00741
3. Spark plugs
The following procedure applies to all of the
spark plugs.

Check the condition of the spark plug.

Check the spark plug type.

Measure the spark plug gap.
Refer to “CHECKING THE SPARK PLUGS”
in chapter 3.
Standard spark plug
CR9EK (NGK)
Spark plug gap
0.6  0.7 mm (0.0236  0.0276 in)

Is the spark plug in good condition, is it of the
correct type, and is its gap within specifica-
tion?
Re-gap or replace
the spark plug.
IGNITION SYSTEMELEC
NOTE:
YESNO
1. Main and ignition fuses

Check the main and ignition fuses for conti-
nuity.
Refer to “CHECKING THE FUSES” in chap-
ter 3.

Are the main and ignition fuses OK?
Replace the fuse(s).
EAS00737
TROUBLESHOOTING
The ignition system fails to operate (no
spark or intermittent spark).
Check:
1. main and ignition fuses
2. battery
3. spark plugs
4. ignition spark gap
5. ignition coil resistance
6. crankshaft position sensor
7. main switch
8. engine stop switch
9. neutral switch
10. sidestand switch
11. clutch switch
12. starting circuit cut-off relay (diode)
13. lean angle cut-off switch
14. wiring connections
(of the entire ignition system)

Before troubleshooting, remove the following
part(s):
1. seat
2. fuel tank
3. side cowlings

Troubleshoot with the following special tool(s).
Ignition checker
90890-06754
Dynamic spark tester
YM-34487
Pocket tester
90890-03112, YU-3112
EAS00738
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8-12
IGNITION SYSTEMELEC
6. Crankshaft position sensor resistance

Disconnect the crankshaft position sensor
coupler from the wire harness.

Connect the pocket tester (Ω
100) to the
crankshaft position sensor coupler as shown.
Positive tester probe
gray
Negative tester probe
black
1
2

Measure the crankshaft position sensor
resistance.
Crankshaft position sensor
resistance
336  504 Ω at 20C
(between gray and black)

Is the crankshaft position sensor OK?
YESNO
Replace the
crankshaft position
sensor.
EAS00749
7. Main switch

Check the main switch for continuity.
Refer to “CHECKING THE SWITCHES”.

Is the main switch OK?
YESNO
Replace the main
switch.
EAS00748EAS00750
8. Engine stop switch

Check the engine stop switch for continuity.
Refer to “CHECKING THE SWITCHES”.

Is the engine stop switch OK?
YESNO
Replace the right
handlebar switch.
EAS00751
9. Neutral switch

Check the neutral switch for continuity.
Refer to “CHECKING THE SWITCHES”.

Is the neutral switch OK?
YESNO
Replace the neutral
switch.
EAS00752
10. Sidestand switch

Check the sidestand switch for continuity.
Refer to “CHECKING THE SWITCHES”.

Is the sidestand switch OK?
YESNO
Replace the side-
stand switch.
EAS00763
11. Clutch switch

Check the clutch switch for continuity.
Refer to “CHECKING THE SWITCHES”.

Is the clutch switch OK?
YESNO
Replace the clutch
switch.
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