warning YAMAHA YZF-R1S 2004 Workshop Manual

4-55
FRONT FORKCHAS
NOTE:
23 Nm (2.3 m
kg, 17 ft
lb)
23 Nm (2.3 m
kg, 17 ft
lb)
17 Nm (1.7 m
kg, 12 ft
lb)
26 Nm (2.6 m
kg, 19 ft
lb)
WARNING
EAS00662
INSTALLING THE FRONT FORK LEGS
The following procedure applies to both of the
front fork legs.
1. Install:

front fork leg
Temporarily tighten the upper and lower
bracket pinch bolts.
Make sure the inner fork tube is flush with the
top of the handlebar holder.
2. Tighten:

under bracket pinch bolt
1

cap bolt 2

handlebar pinch bolt 3

upper bracket pinch bolt 4
Make sure the brake hoses are routed prop-
erly.
3. Adjust:

spring preload

rebound damping

compression damping
Refer to “ADJUSTING THE FRONT FORK
LEGS” in chapter 3.
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4-58
HANDLEBARSCHAS
WARNING
NOTE:
NOTE:
WARNING
WARNING
EAS00667
REMOVING THE HANDLEBARS
1. Stand the motorcycle on a level surface.
Securely support the motorcycle so that
there is no danger of it falling over.
2. Remove:

handlebar grip
1
Blow compressed air between the left handle-
bar and the handlebar grip, and gradually push
the grip off the handlebar.
3. Remove:

throttle cable housing
1

throttle grip 2
While removing the throttle cable housing, pull
back the rubber cover
3.
EAS00669
CHECKING THE HANDLEBARS
1. Check:

left handlebar
1

right handlebar 2
Bends / cracks / damage
Replace.
Do not attempt to straighten bent handle-
bars as this may dangerously weaken them.
EAS00674
INSTALLING THE HANDLEBARS
1. Stand the motorcycle on a level surface.
Securely support the motorcycle so that
there is no danger of it falling over.
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4-60
HANDLEBARSCHAS
NOTE:
WARNING
6. Install:

left handlebar switch
1
Align the projection a on the left handlebar
switch with the hole
b in the left handlebar.
7. Install:

handlebar grip
a. Apply a thin coat of rubber adhesive onto the
end of the left handlebar.
b. Slide the handlebar grip over the end of the
left handlebar.
c. Wipe off any excess rubber adhesive with a
clean rag.
Do not touch the handlebar grip until the
rubber adhesive has fully dried.
8. Adjust:

clutch cable free play
Refer to “ADJUSTING THE CLUTCH
CABLE FREE PLAY” in chapter 3.
Clutch cable free play
(at the end of the clutch lever)
10
15 mm (0.39
0.59 in)
9. Adjust:

throttle cable free play
Refer to “ADJUSTING THE THROTTLE
CABLE FREE PLAY” in chapter 3.
Throttle cable free play
(at the flange of the throttle grip)
3
5 mm (0.12
0.20 in)
CHECKING THE STEERING DAMPER
1. Check:

steering damper body
Damage / oil leaks
Replace.
(It replace with the assembly.)

steering damper rod
Bends / scratch
Replace.
(It replace with the assembly.)

bearing
Damage /pitting
Replace.
(It replace with the assembly.)
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4-63
STEERING HEADCHAS
WARNING
WARNING
EAS00677
REMOVING THE UNDER BRACKET
1. Stand the motorcycle on a level surface.
Securely support the motorcycle so that
there is no danger of it falling over.
2. Remove:

ring nut
1
(with the steering nut wrench 2)
Steering nut wrench
90890–01403, YU-33975
Securely support the lower bracket so that
there is no danger of it falling.
EAS00681
CHECKING THE STEERING HEAD
1. Wash:

bearings

bearing races
Recommended cleaning solvent
Kerosene
2. Check:

bearings
1

bearing races 2
Damage / pitting
Replace.
3. Replace:

bearings

bearing races
a. Remove the bearing races
1 from the steer-
ing head pipe with a long rod
2 and hammer.
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4-66
REAR SHOCK ABSORBER ASSEMBLYCHAS
WARNING
WARNING
EAS00687
HANDLING THE REAR SHOCK ABSORBER
AND GAS CYLINDER
This rear shock absorber and gas cylinder
contain highly compressed nitrogen gas.
Before handling the rear shock absorber or
gas cylinder, read and make sure you under-
stand the following information. The
manufacturer cannot be held responsible
for property damage or personal injury that
may result from improper handling of the
rear shock absorber and gas cylinder.

Do not tamper or attempt to open the rear
shock absorber or gas cylinder.

Do not subject the rear shock absorber or
gas cylinder to an open flame or any other
source of high heat. High heat can cause an
explosion due to excessive gas pressure.

Do not deform or damage the rear shock
absorber or gas cylinder in any way. If the
rear shock absorber, gas cylinder or both
are damaged, damping performance will
suffer.
EAS00689
DISPOSING OF A REAR SHOCK
ABSORBER AND GAS CYLINDER
Gas pressure must be released before dispos-
ing of a rear shock absorber and gas cylinder. To
release the gas pressure, drill a 2
3 mm (0.08

0.12 in) hole through the gas cylinder at a
point 15
20 mm (0.59
0.79 in) from its end
as shown.
Wear eye protection to prevent eye damage
from released gas or metal chips.
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4-67
REAR SHOCK ABSORBER ASSEMBLYCHAS
WARNING
NOTE:
NOTE:
NOTE:
EAS00690
REMOVING THE REAR SHOCK ABSORBER
ASSEMBLY
1. Stand the motorcycle on a level surface.
Becurely support the motorcycle so that
there is no danger of it falling over.
Place the motorcycle on a suitable stand so that
the rear wheel is elevated.
2. Remove:

bottom cowling
Refer to “COWLINGS” in chapter 3.

servo motor
Refer to “EXHAUST PIPE” in chapter 5.
3. Remove:

rear shock absorber assembly lower bolt
1

relay arm-to-swingarm bolt 2
While removing the rear shock absorber as-
sembly lower bolt, hold the swingarm so that it
does not drop down.
4. Remove:

rear shock absorber assembly upper bolt
1

rear shock absorber assembly
Raise the swingarm and then remove the rear
shock absorber assembly from between the
swingarm.
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4-71
SWINGARM AND DRIVE CHAINCHAS
WARNING
NOTE:
NOTE:
EAS00703
REMOVING THE SWINGARM
1. Stand the motorcycle on a level surface.
Securely support the motorcycle so that
there is no danger of it falling over.
Place the motorcycle on a suitable stand so that
the rear wheel is elevated.
2. Remove:

relay arm-to-swingarm bolt
1

connecting arm bolt 2

rear shock absorber assembly lower bolt 3
When removing the rear shock absorber as-
sembly lower bolt, hold the swingarm so that it
does not drop down.
3. Measure:

swingarm side play

swingarm vertical movement
a. Measure the tightening torque of the pivot
shaft nut.
Pivot shaft nut
105 Nm (10.5 m
kg, 76 ft
lb)
b. Measure the swingarm side play
A by mov-
ing the swingarm from side to side.
c. If the swingarm side play is out of specifica-
tion, check the spacers, bearings, washers,
and dust covers.
Swingarm side play
(at the end of the swingarm)
1.0 mm (0.04 in)
d. Check the swingarm vertical movement
B
by moving the swingarm up and down.
If swingarm vertical movement is not smooth
or if there is binding, check the spacers,
bearings, washers, and dust covers.
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4-72
SWINGARM AND DRIVE CHAINCHAS
WARNING
NOTE:
NOTE:
WARNING
EAS00704
REMOVING THE DRIVE CHAIN
1. Stand the motorcycle on a level surface.
Securely support the motorcycle so that
there is no danger of it falling over.
Place the motorcycle on a suitable stand so that
the rear wheel is elevated.
2. Remove:

drive chain
(with the drive chain cutter)
Only cut the drive chain if it or the swingarm is to
be replaced.
EAS00707
CHECKING THE SWINGARM
1. Check:

swingarm
Bends / cracks / damage
Replace.
2. Check:

pivot shaft
Roll the pivot shaft on a flat surface.
Bends
Replace.
Do not attempt to straighten a bent pivot
shaft.
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5-21
CAMSHAFTENG
10 Nm (1.0 m
kg, 7.2 ft
lb)
CAUTION:
WARNING
8. Install:

O-ring
New

timing chain tensioner
1

timing chain tensioner bolts 2
The “arrow” mark a on the timing chain ten-
sioner should face up.
Always use a new O-ring.
9. Turn:

crankshaft
(several full turns clockwise)
10. Check:

“T” mark
a
Make sure the “T” mark on the pickup rotor is
aligned with the crankcase mating sure face
b.

camshaft punch mark
c
Make sure the punch mark c on the cam-
shaft is aligned with the camshaft cap arrow
mark
d.
Out of alignment
Adjust.
Refer to the installation steps above.
11. Measure:

valve clearance
Out of specification
Adjust.
Refer to “ADJUSTING THE VALVE CLEAR-
ANCE” in chapter 3.
12. Install:

pickup coil rotor cover
Refer to “CRANKSHAFT POSITION SEN-
SOR”.
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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.
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