2004 YAMAHA YZF-R1S oil

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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5-59
SHIFT SHAFTENG
Order Job / Part Q’ty Remarks
10
11
12
13Oil seal
Bearing
Bearing
Stopper lever spring1
1
1
1
For installation, reverse the removal
procedure.
22 Nm (2.2 m
kg, 16 ft
lb)
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5-61
SHIFT SHAFTENG
22 Nm (2.2 m
kg, 16 ft
lb)
NOTE: CHECKING THE SHIFT SHAFT
1. Check:

shift shaft
1
Bends / damage / wear
replace.

shift shaft spring
2

collar 3
Damage / wear
Replace.
CHECKING THE STOPPER LEVER
1. Check:

stopper lever
1
Bends / damage
Replace.
Roller turns roughly
Replace the stopper
lever.
INSTALLING THE SHIFT SHAFT
1. Install:

washer

stopper lever
1

stopper screw 2
LOCTITE

stopper lever spring 3
2. Install:

washer

collar

shift shaft spring
1

shift shaft 2

Mesh the stopper lever with the shift drum seg-
ment assembly.

Lubricate the oil seal lips with lithium soap
base grease.

Install the end of the shift shaft spring onto the
shift shaft spring stopper.
3. Install:

Washer
1

circlip 2 New
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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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5-64
OIL PAN AND OIL PUMPENG
Order Job / Part Q’ty Remarks
9
10
11
12
13
14
15
16
17
18Oil pipe
Oil delivery pipe
Relief valve assembly
Oil / water pump assembly drive
chain guide
Collar
Oil / water pump assembly drive
sprocket
Washer
Oil / water pump assembly drive chain
Dowel pin
Oil / water pump assembly1
1
1
1
1
1
1
1
1
1
For installation, reverse the removal
procedure.
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)
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5-65
Order Job / Part Q’ty Remarks
Disassembling the oil pump
Oil / water pump driven sprocket
Collar
Oil pump housing
Bearing
Pin
Oil pump outer rotor
Oil pump inner rotor
Pin1
1
1
1
2
1
1
1Disassemble the parts in the order listed.
For assembly, reverse the disassembly
procedure.
1
2
3
4
5
6
7
8
15 Nm (1.5 m
kg, 11 ft
lb)
OIL PAN AND OIL PUMPENG
EAS00360
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5-66
OIL PAN AND OIL PUMPENG
NOTE:
EAS00362
REMOVING THE OIL PAN
1. Remove:

oil level switch
1

oil pan 2

oil pan gasket

dowel pins
Loosen each bolt 1 / 4 of a turn at a time, in
stages and in a crisscross pattern. After all of
the bolts are fully loosened, remove them.
CHECKING THE SPROCKET AND CHAIN
1. Check:

oil / water pump assembly drive sprocket
1
Cracks / damage / wear
Replace the de-
fective part(-s).
2. Check:

oil / water pump assembly drive chain
1
Damage / stiffness
Replace the oil / water
pump assembly drive chain and oil / water
pump assembly drive sprocket as a set.
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5-67
OIL PAN AND OIL PUMPENG
EAS00364
CHECKING THE OIL PUMP
1. Check:

oil pump driven gear
1

oil pump rotor housing 2

oil pump cover
Cracks / damage / wear
Replace the de-
fective part(s).
2. Measure:

inner-rotor-to-outer-rotor-tip clearance
a

outer-rotor-to-oil-pump-housing clearance
b
1Inner rotor
2Outer rotor
3Oil pump housing
Inner-rotor-to-outer-rotor-tip
clearance
0.01
0.10 mm
(0.0004
0.0039 in)
: 0.18 mm (0.0071 in)
Outer-rotor-to-oil-pump-housing
clearance
0.09
0.15 mm
(0.0035
0.0059 in)
: 0.22 mm (0.0087 in)
3. Check:

oil pump operation
Rough movement
Repeat steps (1) and
(2) or replace the defective part(s).
EAS00365
CHECKING THE RELIEF VALVE
1. Check:

relief valve body
1

relief valve 2

spring 3

O-ring 4
Damage / wear
Replace the defective
part(s).
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