wheel bolts YAMAHA YZF-R1S 2004 Service Manual

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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3-49
ADJUSTING THE DRIVE CHAIN SLACK
CHK
ADJ
NOTE:
CAUTION:
WARNING
NOTE:
EAS00140
ADJUSTING THE DRIVE CHAIN SLACK
The drive chain slack must be checked at the
tightest point on the chain.
A drive chain that is too tight will overload
the engine and other vital parts, and one that
is too loose can skip and damage the swin-
garm or cause an accident. Therefore, keep
the drive chain slack within the specified
limits.
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. Spin the rear wheel several times and find
the tightest position of drive chain.
3. Check:

drive chain slack
a
Out of specification
Adjust.
Drive chain slack
25
35 mm (0.98
1.38 in)
4. Adjust:

drive chain slack
a. Loosen the wheel axle nut
1.
b. Loosen both locknuts
2.
c. Turn both adjusting bolts
3 in direction a or
b until the specified drive chain slack is ob-
tained.
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4-5
FRONT WHEEL AND BRAKE DISCSCHAS
NOTE:
EAS00533
CHECKING THE BRAKE DISCS
The following procedure applies to all of the
brake discs.
1. Check:

brake disc
Damage / galling
Replace.
2. Measure:

brake disc deflection
Out of specification
Correct the brake disc
deflection or replace the brake disc.
Brake disc deflection limit
(maximum)
Front : 0.1 mm (0.004 in)
Rear : 0.15 mm (0.006 in)
a. Place the motorcycle on a suitable stand so
that the wheel is elevated.
b. Before measuring the front brake disc deflec-
tion, turn the handlebars to the left or right to
ensure that the front wheel is stationary.
c. Remove the brake caliper.
d. Hold the dial gauge at a right angle against
the brake disc surface.
e. Measure the deflection 1.5 mm (0.06 in) be-
low the edge of the brake disc.
3. Measure:

brake disc thickness
Measure the brake disc thickness at a few
different locations.
Out of specification
Replace.
Brake disc thickness limit
(minimum)
Front : 4.0 mm (0.16 in)
Rear : 4.5 mm (0.18 in)
4. Adjust:

brake disc deflection
a. Remove the brake disc.
b. Rotate the brake disc by one bolt hole.
c. Install the brake disc.
Tighten the brake disc bolts in stages and in a
crisscross pattern.
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4-14
REAR WHEEL AND BRAKE DISCCHAS
NOTE:
150 Nm (15 m
kg, 108 ft
lb)
27 Nm (2.7 m
kg, 20 ft
lb)
22 Nm (2.2 m
kg, 16 ft
lb)
NOTE: 2. Replace:

rear wheel sprocket
a. Remove the self-locking nuts and the rear
wheel sprocket.
b. Clean the rear wheel drive hub with a clean
cloth, especially the surfaces that contact the
sprocket.
c. Install the new rear wheel sprocket.
Rear wheel sprocket self-locking
nut
100 Nm (10 m
kg, 72 ft
lb)
Tighten the self-locking nuts in stages and in a
crisscross pattern.
EAS00572
INSTALLING THE REAR WHEEL
1. Lubricate:

wheel axle

wheel bearings

oil seal lips
Recommended lubricant
Lithium-soap-based grease
2. Tighten:

wheel axle nut

brake caliper bolts (front)
(rear)
EAS00575
ADJUSTING THE REAR WHEEL STATIC
BALANCE

After replacing the tire, wheel or both, the rear
wheel static balance should be adjusted.

Adjust the rear wheel static balance with the
brake disc and rear wheel drive hub installed.
1. Adjust:

rear wheel static balance
Refer to “ADJUSTING THE FRONT WHEEL
STATIC BALANCE”.
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4-47
FRONT FORKCHAS
WARNING
NOTE:
WARNING
EAS00649
REMOVING THE FRONT FORK LEGS
The following procedure applies to both of the
front fork legs.
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 front wheel is elevated.
2. Remove

front wheel

front brake caliper
Refer to “FRONT WHEEL AND BRAKE
DISCS”.
3. Remove:

Side Cowlings
Refer to “COWLINGS” in chapter 3.

handlebar
4. Loosen:

handlebar pinch bolt
1

upper bracket pinch bolt 2

cap bolt 3

under bracket pinch bolt 4
Before loosening the upper and under
bracket pinch bolts, support the front fork
leg.
5. Remove:

front fork leg
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