2004 YAMAHA YZF-R1S oil

5-98
TRANSMISSIONENG
Order Job / Part Q’ty Remarks
13
14
15
16
17Main axle retainer
Main axle assembly
Oil pipe
O-ring
Oil baffle plate1
1
1
2
1
For installation, reverse the removal
procedure.
12 Nm (1.2 m
kg, 8.7 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)
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5-102
TRANSMISSIONENG
Order Job / Part Q’ty Remarks
6th wheel gear
Circlip
Washer
Collar
2nd wheel gear
Collar
Oil seal
Bearing
Drive axle1
1
1
1
1
1
1
1
1
For installation, reverse the removal
procedure.
15
16
17
18
19
20
21
22
23
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5-103
TRANSMISSIONENG
REMOVING THE TRANSMISSION
1. Remove:

drive axle assembly
1

shift drum retainers 2

shift fork guide bars

shift fork “L” and “R”

shift drum assembly

shift fork “C”
2. Remove:

bearing housing
1

main axle assembly 2
a. Insert two bolts 3 of the proper size, as
shown in the illustration, into the main axle
assembly bearing housing.
b. Tighten the bolts until they contact the crank-
case surface.
c. Continue tightening the bolts until the main
axle assembly comes free from the upper
crankcase.
3. Remove:

oil pipe
1

bearing 2
EAS00421
CHECKING THE SHIFT FORKS
The following procedure applies to all of the shift
forks.
1. Check:

shift fork cam follower
1

shift fork pawl 2
Bends / damage / scoring / wear
Replace
the shift fork.
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5-105
TRANSMISSIONENG
NOTE:
12 Nm (1.2 m
kg, 8.7 ft
lb)
10 Nm (1.0 m
kg, 7.2 ft
lb)
NOTE: 2. Measure:

drive axle runout
(with a centering device and dial gauge
1)
Out of specification
Replace the drive
axle.
Drive axle runout limit
0.08 mm (0.0032 in)
3. Check:

transmission gears
Blue discoloration / pitting / wear
Replace
the defective gear(s).

transmission gear dogs
Cracks / damage / rounded edges
Replace
the defective gear(s).
INSTALLING THE TRANSMISSION
1. Install:

bearing
1
Make the seal side of bearing face to the outside
and install it close to the right end face of the
crankcase.

oil pipe
2
2. Install:

main axle assembly
1

bearing housing 2
LOCTITE

shift fork “C”

shift drum assembly

shift fork guide bar

shift fork guide bar retainer
LOCTITE

The embossed marks on the shift forks should
face towards the right side of the engine and
be in the following sequence: “R”, “C”, “L”.

Carefully position the shift forks so that they
are installed correctly into the transmission
gears.

Install shift fork “C” into the groove in the 3rd
and 4th pinion gear on the main axle.
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5-106
TRANSMISSIONENG
10 Nm (1.0 m
kg, 7.2 ft
lb)
NOTE:
NOTE: 3. Install:

shift fork “L”
1 and “R” 2

drive axle assembly 3

shift fork guide bar

shift fork guide bar retainer
4
LOCTITE

Install shift fork “L” into the groove in the 6th
wheel gear and shift fork “R” into the groove in
the 5th wheel gear on the drive axle.

Make sure that the drive axle bearing circlip
a
is inserted into the grooves in the upper crank-
case.
4. Check:

transmission
Rough movement
Repair.
Oil each gear, shaft, and bearing thoroughly.
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6-2
6
RADIATORCOOL
Order Job / Part Q’ty Remarks
6
7
8
9
10
11Radiator inlet pipe
Oil cooler outlet hose
Water pump breather hose
Radiator outlet hose
Water pump inlet pipe
O-ring1
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)
5 Nm (0.5 m
kg, 3.6 ft
lb)
10 Nm (1.0 m
kg, 7.2 ft
lb)
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6-5
Order Job / Part Q’ty Remarks
1
2
3
4
5
6
7
8
9Removing the oil cooler
Engine oil
Oil cooler inlet hose
Bolt
Washer
Oil cooler
O-ring
Water pump outlet pipe
O-ring
Water jacket joint inlet hose
O-ring1
1
1
1
1
1
1
1
1Remove the parts in the order listed.
Drain.
Refer to “CHANGING THE ENGINE OIL”
in chapter 3.
10 Nm (1.0 m
kg, 7.2 ft
lb)
10 Nm (1.0 m
kg, 7.2 ft
lb)
63 Nm (6.3 m
kg, 46 ft
lb)
OIL COOLERCOOL
EAS00457
OIL COOLER
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6-6
OIL COOLERCOOL
Order Job / Part Q’ty Remarks
10
11
12Water jacket joint
Stay
O-ring1
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)
63 Nm (6.3 m
kg, 46 ft
lb)
ProCarManuals.com