oil YAMAHA YZF-R1S 2004 Manual Online

5-11
Order Job / Part Q’ty Remarks
1
2
3
4Removing the cylinder head cover
Fuel tank
Side and bottom cowlings
Throttle body assembly
Radiator assembly
Air cut-off valve
Ignition coil
Spark plug
Cylinder head cover
Cylinder head cover gasket4
4
1
1Remove the parts in the order listed.
Refer to “FUEL TANK” in chapter 3.
Refer to “COWLINGS” in chapter 3.
Refer to “THROTTLE BODIES” in
chapter 7.
Refer to “RADIATOR” in chapter 3.
Refer to “AIR INDUCTION SYSTEM” in
chapter 7.
13 Nm (1.3 m
kg, 9.4 ft
lb)
8 Nm (0.8 m
kg, 5.7 ft
lb)
12 Nm (1.2 m
kg, 8.7 ft
lb)
CAMSHAFTENG
EAS00194
CAMSHAFT
CYLINDER HEAD COVER
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5-18
CAMSHAFTENG
NOTE:
NOTE:
NOTE:
3. Install:

timing chain tensioner spring

timing chain tension rod
1
Prior to installing the timing chain tensioner rod,
drain the engine oil from the timing chain ten-
sioner housing.
a. Install the timing chain tensioner spring and
timing chain tensioner rod
1.
b. Squeeze the timing chain tensioner clip
2
and push the timing chain tensioner rod 3.
When the timing chain tensioner rod
3 is
pushed while holding the grip of the timing chain
tensioner clip
2, make sure not to release the
timing chain tensioner rod
3 before releasing
the timing chain tensioner clip
2. (Otherwise,
the timing chain tensioner rod
3 may run off.)
c. Hook the clip
4 to the timing chain tensioner
rod
3.
Hook the timing chain tensioner rod pin
5 to the
center of the clip
4. After the installation, check
that the clip
4 can come off by its own weight by
pushing the timing chain tensioner rod
3 at the
position of installation.
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5-20
CAMSHAFTENG
10 Nm (1.0 m
kg, 7.2 ft
lb)
NOTE:
CAUTION:
24 Nm (2.4 m
kg, 17 ft
lb)
CAUTION:
5. Install:

camshaft cap bolts
Tighten the camshaft cap bolts in stages and in
a crisscross pattern, working from the inner
caps out.

Lubricate the camshaft cap bolts with the
engine oil.

The camshaft cap bolts must be tightened
evenly or damage to the cylinder head,
camshaft caps, and camshafts will result.

Do not turn the crankshaft when installing
the camshaft to avoid damage or improper
valve timing.
6. Tighten:

camshaft sprocket bolts
1
Camshaft wrench
90890-04143
Be sure to tighten the camshaft sprocket
bolts to the specified torque to avoid the
possibility of the bolts coming loose and
damaging the engine.
7. Align:

camshaft punch mark
a
Align the camshaft punch mark a and the
camshaft cap arrow mark
b.
Camshaft wrench
90890-04143
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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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5-24
CYLINDER HEADENG
8 Nm (0.8 m
kg, 5.8 ft
lb)
NOTE:
NOTE:
19 Nm (1.9 m
kg, 14 ft
lb)
67 Nm (6.7 m
kg, 48 ft
lb)
12 Nm (1.2 m
kg, 8.7 ft
lb)
NOTE:
EAS00233
INSTALLING THE CYLINDER HEAD
1. Check:

cylinder head bolts
1
Retighten the cylinder head bolts to specifica-
tion, before installing the cylinder head.
2. Install:

gasket
New
1

dowel pins
3. Install:

cylinder head
Pass the timing chain through the timing chain
cavity.
4. Tighten:

cylinder head nuts
1
10
1st
2nd

cylinder head bolts
11 12

First, tighten the nuts 1
10 to approximate-
ly 19 Nm (1.9 m
kg, 14 ft
lb) with a torque
wrench, and then tighten the 67 Nm (6.7 m
kg,
48 ft
lb).

Lubricate the cylinder head nuts with engine
oil.

Tighten the cylinder head nuts in the proper
tightening sequence as shown and torque
them in two stages.
5. Install:

exhaust camshaft

intake camshaft
Refer to “INSTALLING THE CAMSHAFTS”.
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5-25
VALVES AND VALVE SPRINGSENG
Order Job / Part Q’ty Remarks
1
2
3
4
5
6
7
8
9Removing the valves and valve
springs
Cylinder head
Intake valve lifter
Intake valve pad
Intake valve cotter
Intake valve upper spring seat
Intake valve spring
Intake valve oil seal
Intake valve lower spring seat
Intake valve
Intake valve guide12
12
24
12
12
12
12
12
12Remove the parts in the order listed.
Refer to “CYLINDER HEAD”.
EAS00236
VALVES AND VALVE SPRINGS
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5-26
Order Job / Part Q’ty Remarks
10
11
12
13
14
15
16
17
18Exhaust valve lifter
Exhaust valve pad
Exhaust valve cotter
Exhaust valve upper spring seat
Exhaust valve spring
Exhaust valve oil seal
Exhaust valve lower spring seat
Exhaust valve
Exhaust valve guide8
8
16
8
8
8
8
8
8
For installation, reverse the removal
procedure.
VALVES AND VALVE SPRINGSENG
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5-29
VALVES AND VALVE SPRINGSENG
NOTE:
NOTE:
After replacing the valve guide, reface the valve
seat.
Valve guide remover
Intake (4.0 mm, 0.16 in)
90890-04111
Exhaust (4.5 mm, 0.18 in)
90890-04116, YM-4116
Valve guide installer
Intake (4.0 mm, 0.16 in)
90890-04112
Exhaust (4.5 mm, 0.18 in)
90890-04117, YM-4117
Valve guide reamer
Intake (4.0 mm, 0.16 in)
90890-04113
Exhaust (4.5 mm, 0.18 in)
90890-04118, YM-4118
3. Eliminate:

carbon deposits
(from the valve face and valve seat)
4. Check:

valve face
Pitting / wear
Grind the valve face.

valve stem end
Mushroom shape or diameter larger than the
body of the valve stem
Replace the valve.
5. Measure:

valve margin thickness
a
Out of specification
Replace the valve.
Valve margin thickness
0.5
0.9 mm
(0.0197
0.0354 in)
: 0.5 mm (0.02 in)
6. Measure:

valve stem runout
Out of specification
Replace the valve.

When installing a new valve, always replace
the valve guide.

If the valve is removed or replaced, always re-
place the oil seal.
Valve stem runout
0.01 mm (0.0004 in)
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5-31
VALVES AND VALVE SPRINGSENG
CAUTION:
NOTE:
a. Apply a coarse lapping compound a to the
valve face.
Do not let the lapping compound enter the
gap between the valve stem and the valve
guide.
b. Apply molybdenum disulfide oil onto the
valve stem.
c. Install the valve into the cylinder head.
d. Turn the valve until the valve face and valve
seat are evenly polished, then clean off all of
the lapping compound.
For the best lapping results, lightly tap the valve
seat while rotating the valve back and forth be-
tween your hands.
e. Apply a fine lapping compound to the valve
face and repeat the above steps.
f. After every lapping procedure, be sure to
clean off all of the lapping compound from
the valve face and valve seat.
g. Apply Mechanic’s blueing dye (Dykem) onto
the valve face.
h. Install the valve into the cylinder head.
i. Press the valve through the valve guide and
onto the valve seat to make a clear impres-
sion.
j. Measure the valve seat width
a again. If the
valve seat width is out of specification, reface
and lap the valve seat.
EAS00241
CHECKING THE VALVE SPRINGS
The following procedure applies to all of the
valve springs.
1. Measure:

valve spring free length
a
Out of specification
Replace the valve
spring.
Valve spring free length
Intake valve spring
39.3 mm (1.55 in)
: 37.3 mm (1.47 in)
Exhaust valve spring
39.3 mm (1.55 in)
: 37.3 mm (1.47 in)
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5-32
VALVES AND VALVE SPRINGSENG
2. Measure:

compressed valve spring force
a
Out of specification
Replace the valve
spring.
bInstalled length
Compressed valve spring force
(installed)
Intake valve spring
145.9
167.9 N
(14.88
17.12 kg,
32.80
37.74 lb) at
32.65 mm (1.285 in)
Exhaust valve spring
164.1
188.9 N
(16.73
19.26 kg,
36.89
42.46 lb) at
32.82 mm (12.92 in)
3. Measure:

valve spring tilt
a
Out of specification
Replace the valve
spring.
Spring tilt limit
Intake valve spring
1.7 mm (0.07 in)
Exhaust valve spring
1.7 mm (0.07 in)
EAS00242
CHECKING THE VALVE LIFTERS
The following procedure applies to all of the
valve lifters.
1. Check:

valve lifter
Damage / scratches
Replace the valve lift-
ers and cylinder head.
EAS00245
INSTALLING THE VALVES
The following procedure applies to all of the
valves and related components.
1. Deburr:

valve stem end
(with an oil stone)
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