engine oil YAMAHA YZF-R1S 2004 Workshop Manual

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
ProCarManuals.com

5-54
CLUTCHENG
NOTE:
EAS00286
CHECKING THE PRESSURE PLATE
1. Check:

pressure plate
1
Cracks / damage
Replace.

bearing
2
Damage / wear
Replace.
EAS00287
CHECKING THE PULL LEVER SHAFT AND
PULL ROD
1. Check:

pull lever shaft pinion gear teeth
1

pull rod teeth 2
Damage / wear
Replace the pull rod and
pull lever shaft pinion gear as a set.
2. Check:

pull rod bearing
Damage / wear
Replace.
INSTALLING THE CLUTCH
1. Install:

clutch damper spring seat
1

clutch damper spring 2
2. Install:

friction plate 3
1

clutch plate 2 2
Lubricate the engine oil.
ProCarManuals.com

5-56
CLUTCHENG
NOTE:
10 Nm (1.0 m
kg, 7.2 ft
lb)
NOTE:
NOTE: 6. Lubricate:

friction plates

clutch plates
(with the recommended lubricant)
Recommended lubricant
Engine oil
7. Install:

friction plate 2

clutch plate 1
1
8. Install:

friction plate 1
1
Install the last friction plate shifting half phase.
9. Install:

bearing

pull rod
1

pressure plate 2

clutch springs

clutch spring bolts
3
Tighten the clutch spring bolts in stages and in a
crisscross pattern.
10. Install:

pull lever
In stall the pull lever with the “” mark facing to-
ward upper side.
ProCarManuals.com

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
ProCarManuals.com

5-68
OIL PAN AND OIL PUMPENG
EAS00367
CHECKING THE OIL DELIVERY PIPE AND
OIL PIPE
1. Check:

oil delivery pipe
1

oil pipe 2
Damage
Replace.
Obstruction
Wash and blow out with com-
pressed air.
EAS00368
CHECKING THE OIL STRAINER
1. Check:

oil strainer
1
Damage
Replace.
Contaminants
Clean with solvent.
EAS00373
CHECKING THE OIL NOZZLES
The following procedure applies to all of the oil
nozzles.
1. Check:

oil nozzle
1
Damage / wear
Replace the oil nozzle.

O-ring
2
Damage / wear
Replace.

oil nozzle passage
Obstruction
Blow out with compressed air.
EAS00374
ASSEMBLING THE OIL PUMP
1. Lubricate:

inner rotor

outer rotor

oil pump shaft
(with the recommended lubricant)
Recommended lubricant
Engine oil
ProCarManuals.com

5-71
OIL PAN AND OIL PUMPENG
12 Nm (1.2 m
kg, 8.7 ft
lb)
10 Nm (1.0 m
kg, 7.2 ft
lb)
43Nm (4.3 m
kg, 31 ft
lb)
WARNING
NOTE:
EAS00380
INSTALLING THE OIL PAN
1. Install:

dowel pins

gasket
New

oil pan
1

oil level switch 2

engine oil drain bolt 3
Always use new copper washers.

Tighten the oil pan bolts in stages and in a
crisscross pattern.

Lubricate the oil level switch O-ring with en-
gine oil.
ProCarManuals.com

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
ProCarManuals.com

5-75
CRANKCASEENG
NOTE:
EAS00399
CHECKING THE CRANKCASE
1. Thoroughly wash the crankcase halves in a
mild solvent.
2. Thoroughly clean all the gasket surfaces and
crankcase mating surfaces.
3. Check:

crankcase
Cracks / damage
Replace.

oil delivery passages
Obstruction
Blow out with compressed air.
EAS00401
CHECKING THE BEARINGS AND OIL
SEALS
1. Check:

bearings
Clean and lubricate the bearings, then rotate
the inner race with your finger.
Rough movement
Replace.
2. Check:

oil seals
Damage / wear
Replace.
ASSEMBLING THE CRANKCASE
1. Lubricate:

crankshaft journal bearings
(with the recommended lubricant)
Recommended lubricant
Engine oil
2. Apply:

sealant
Yamaha bond No. 1215
90890-85505, ACC-1109-05-01
Do not allow any sealant to come into contact
with the oil gallery or crankshaft journal bear-
ings. Do not apply sealant to within 2
3 mm
(0.08
0.12 in) of the crankshaft journal bear-
ings.
ProCarManuals.com

5-76
CRANKCASEENG
CAUTION:
NOTE:
3. Install:

dowel pin
4. Set the shift drum assembly and transmis-
sion gears in the neutral position.
5. Install:

lower crankcase
1
(onto the upper crankcase 2)
Before tightening the crankcase bolts, make
sure that the transmission gears shift cor-
rectly when the shift drum assembly is
turned by hand.
6. Install:

crankcase bolts

Lubricate the bolt threads with engine oil.

Install a washer on bolts
1
10 and 22.

Seal bolt
18

Tighten the bolts in the tightening sequence
cast on the crankcase.
M9  105 mm (4.1 in) bolts:
1
10
M8  60 mm (2.4 in) bolt: 11 LOCTITE
M8  60 mm (2.4 in) bolts: 12, 16
M6  70 mm (2.8 in) bolts: 19, 21, 23
M6  65 mm (2.5 in) bolts: 17, 18
M6  60 mm (2.4 in) bolts: 22, 24, 25
M6  50 mm (2.0 in) bolts: 20, 26
M8  50 mm (2.0 in) bolts: 13
15
Crankcase bolt
Bolt
1
10
1st: 20 Nm (2.0 m
kg, 14 ft
lb)
2nd*: 20 Nm (2.0 m
kg, 14 ft
lb)
3rd: +60
Bolt
11
16
24 Nm (2.4 m
kg, 17 ft
lb)
Bolt
17
26
12 Nm (1.2 m
kg, 8.7 ft
lb)
* Following the tightening order, loosen the bolt
one by one and then retighten it to the specific
torque.
ProCarManuals.com

5-87
CONNECTING RODS AND PISTONSENG
NOTE:
NOTE:
Be sure to install the piston rings so that the
manufacturer’s marks or numbers
a face up.
2. Install:

piston
1
(onto the respective connecting rod 2)

piston pin
3

piston pin clip New 4

Apply engine oil onto the piston pin.

Make sure that the “Y” mark
a on the connect-
ing rod faces left when the arrow mark
b on
the piston is pointing up. Refer to the illustra-
tion.

Reinstall each piston into its original cylinder
(numbering order starting from the left: #1 to
#4).
3. Lubricate:

piston

piston rings

cylinder
(with the recommended lubricant)
Recommended lubricant
Engine oil
4. Offset:

piston ring end gaps
aTop ring
bLower oil ring rail
cUpper oil ring rail
d2nd ring
eOil ring expander
5. Lubricate:

crankshaft pins

big end bearings

connecting rod big end inner surface
(with the recommended lubricant)
Recommended lubricant
Engine oil
ProCarManuals.com