2004 YAMAHA YZF-R1S oil

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
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5-69
OIL PAN AND OIL PUMPENG
NOTE:
15 Nm (1.5 m
kg, 11 ft
lb)
NOTE:
12 Nm (1.2 m
kg, 8.7 ft
lb)
2. Install:

pin
1

inner rotor 2

outer rotor 3

oil pump housing 4
When installing the inner rotor, align the pin 1 in
the oil pump shaft with the groove
a in the inner
rotor
2.
3. Install:

oil / water pump driven sprocket
1
LOCTITE
5VY mark of the oil / water pump driven gear is
installed at oil pump side.
4. Check:

oil pump operation
Refer to “CHECKING THE OIL PUMP”.
INSTALLING THE OIL / WATER PUMP
ASSEMBLY
1. Install:

O-ring
New

oil / water pump assembly
1

dowel pin

bolts
2
LOCTITE
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5-70
OIL PAN AND OIL PUMPENG
NOTE:
CAUTION:
10 Nm (1.0 m
kg, 7.2 ft
lb)
NOTE:
10 Nm (1.0 m
kg, 7.2 ft
lb)
10 Nm (1.0 m
kg, 7.2 ft
lb)
2. Install:

washer

oil / water pump assembly drive chain
1

oil / water pump assembly drive sprocket 2

collar
Install the oil / water pump assembly drive chain
1 onto the oil / water pump assembly drive
sprocket
2.
After installing the oil / water pump assem-
bly drive chain and drive sprocket, make
sure the oil / water pump turns smoothly.
3. Install:

oil / water pump assembly drive chain guide
1
LOCTITE
“UP” mark of the oil / water pump assembly drive
chain guide is upward.
4. Install:

oil delivery pipe
1
LOCTITE
5. Install:

relief valve
1

O-ring New

oil strainer
2
LOCTITE

O-ring New

oil pipe
3

O-ring New

drain pipe
4

O-ring New
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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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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
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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.
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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.
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5-77
Order Job / Part Q’ty Remarks
1
2
3
4
5
6
7
8
9
10
11
12Removing the connecting rods and
pistons
Lower crankcase
Connecting rod cap
Big end lower bearing
Big end upper bearing
Piston pin clip
Piston pin
Piston
Connecting rod
Top ring
2nd ring
Oil ring
Cylinder
Cylinder gasket4
4
4
8
4
4
4
4
4
4
1
1Remove the parts in the order listed.
Refer to “CRANKCASE”.
For installation, reverse the removal
procedure.
20 Nm (2.0 m
kg, 14 ft
lb) +150
8 Nm (0.8 m
kg, 5.8 ft
lb)
CONNECTING RODS AND PISTONSENG
EAS00252
CONNECTING RODS AND PISTONS
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