2004 YAMAHA YZF-R1S recommended oil

3-61
CHECKING AND LUBRICATING THE CABLES /
LUBRICATING THE LEVERS AND PEDALS /
LUBRICATING THE SIDESTAND / LUBRICATING THE REAR SUSPENSIONCHK
ADJ
WARNING
NOTE:
EAS00170
CHECKING AND LUBRICATING THE
CABLES
The following procedure applies to all of the in-
ner and outer cables.
Damaged outer cable may cause the cable to
corrode and interfere with its movement. Re-
place damaged outer cable and inner cables
as soon as possible.
1. Check:

outer cable
Damage
Replace.
2. Check:

cable operation
Rough movement
Lubricate.
Recommended lubricant
Engine oil or a suitable cable
lubricant
Hold the cable end upright and pour a few drops
of lubricant into the cable sheath or use a suit-
able lubricating device.
EAS00171
LUBRICATING THE LEVERS AND PEDALS
Lubricate the pivoting point and metal-to-metal
moving parts of the levers and pedals.
Recommended lubricant
Lithium-soap-based grease
EAS00172
LUBRICATING THE SIDESTAND
Lubricate the pivoting point and metal-to-metal
moving parts of the sidestand.
Recommended lubricant
Lithium-soap-based grease
EAS00174
LUBRICATING THE REAR SUSPENSION
Lubricate the pivoting point and metal-to-metal
moving parts of the rear suspension.
Recommended lubricant
Molybdenum-disulfide grease
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4-6
FRONT WHEEL AND BRAKE DISCSCHAS
NOTE:
91 Nm (9.1 m
kg, 66 ft
lb)
20 Nm (2.0 m
kg, 14 ft
lb)
CAUTION:
Brake disc bolt
Front : 18 Nm (1.8 m
kg, 13 ft
lb)
Rear : 30 Nm (3.0 m
kg, 22 ft
lb)
LOCTITE

d. Measure the brake disc deflection.
e. If out of specification, repeat the adjustment
steps until the brake disc deflection is within
specification.
f. If the brake disc deflection cannot be brought
within specification, replace the brake disc.
EAS00545
INSTALLING THE FRONT WHEEL
The following procedure applies to both brake
discs.
1. Lubricate:

wheel axle

oil seal lips
Recommended lubricant
Lithium-soap-based grease
2. Lift the wheel up between the fork legs.
3. Insert the wheel axle.
Install the tire and wheel with the mark
1 point-
ing in the direction of wheel rotation.
4. Lower the front wheel so that it is on the
ground.
5. Tighten:

wheel axle

wheel axle pinch bolt
Before tightening the wheel axle nut, push
down hard on the handlebars several times
and check if the front fork rebounds smooth-
ly.
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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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4-30
FRONT AND REAR BRAKESCHAS
NOTE:
WARNING
CAUTION:

While holding the brake hose, tighten the
union bolt.

Turn the handlebars to the left and right to
make sure the brake hose does not touch oth-
er parts (e.g., wire harness, cables, leads).
Correct if necessary.
4. Fill:

brake fluid reservoir
(with the specified amount of the recom-
mended brake fluid)
Recommended brake fluid
DOT 4

Use only the designated brake fluid. Other
brake fluids may cause the rubber seals to
deteriorate, causing leakage and poor
brake performance.

Refill with the same type of brake fluid that
is already in the system. Mixing brake
fluids may result in a harmful chemical
reaction, leading to poor brake perfor-
mance.

When refilling, be careful that water does
not enter the brake fluid reservoir. Water
will significantly lower the boiling point of
the brake fluid and could cause vapor lock.
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean
up any spilt brake fluid immediately.
5. Bleed:

brake system
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
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4-32
FRONT AND REAR BRAKESCHAS
WARNING
CAUTION:

Use only the designated brake fluid. Other
brake fluids may cause the rubber seals to
deteriorate, causing leakage and poor
brake performance.

Refill with the same type of brake fluid that
is already in the system. Mixing brake
fluids may result in a harmful chemical
reaction, leading to poor brake perfor-
mance.

When refilling, be careful that water does
not enter the brake fluid reservoir. Water
will significantly lower the boiling point of
the brake fluid and could cause vapor lock.
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean
up any spilt brake fluid immediately.
4. Bleed:

brake system
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
5. Check:

brake fluid level
Below the minimum level mark
a
Add the
recommended brake fluid to the proper level.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” in chapter 3.
6. Adjust:

rear brake light operation timing
Refer to “ADJUSTING THE REAR BRAKE
LIGHT SWITCH” in chapter 3.
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4-41
FRONT AND REAR BRAKESCHAS
WARNING
CAUTION:
3. Fill:

brake fluid reservoir
(with the specified amount of the recom-
mended brake fluid)
Recommended brake fluid
DOT 4

Use only the designated brake fluid. Other
brake fluids may cause the rubber seals to
deteriorate, causing leakage and poor
brake performance.

Refill with the same type of brake fluid that
is already in the system. Mixing brake
fluids may result in a harmful chemical
reaction, leading to poor brake perfor-
mance.

When refilling, be careful that water does
not enter the brake fluid reservoir. Water
will significantly lower the boiling point of
the brake fluid and could cause vapor lock.
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean
up any spilt brake fluid immediately.
4. Bleed:

brake system
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM“ in chapter 3.
5. Check:

brake fluid level
Below the minimum level mark
a
Add the
recommended brake fluid to the proper level.
Refer to ”CHECKING THE BRAKE FLUID
LEVEL“ in chapter 3.
6. Check:

brake lever operation
Soft or spongy feeling
Bleed the brake
system.
Refer to ”BLEEDING THE HYDRAULIC
BRAKE SYSTEM“ in chapter 3.
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4-43
FRONT AND REAR BRAKESCHAS
WARNING
CAUTION:
2. Fill:

brake fluid reservoir
(with the specified amount of the recom-
mended brake fluid)
Recommended brake fluid
DOT 4

Use only the designated brake fluid. Other
brake fluids may cause the rubber seals to
deteriorate, causing leakage and poor
brake performance.

Refill with the same type of brake fluid that
is already in the system. Mixing brake
fluids may result in a harmful chemical
reaction, leading to poor brake perfor-
mance.

When refilling, be careful that water does
not enter the brake fluid reservoir. Water
will significantly lower the boiling point of
the brake fluid and could cause vapor lock.
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean
up any spilt brake fluid immediately.
3. Bleed:

brake system
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
4. Check:

brake fluid level
Below the minimum level mark
a
Add the
recommended brake fluid to the proper level.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” in chapter 3.
5. Check:

brake pedal operation
Soft or spongy feeling
Bleed the brake
system.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
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4-51
FRONT FORKCHAS
WARNING
CAUTION:
23 Nm (2.3 m
kg, 17 ft
lb)
NOTE:
Always use new copper washer.
Allow the damper rod assembly to slide
slowly down the inner tube
1 until it pro-
trudes from the bottom of the inner tube. Be
careful not to damage the inner tube.
2. Lubricate:

inner tube’s outer surface
Recommended lubricant
Suspension oil “01” or
equivalent
3. Tighten:

damper rod assembly bolt
1
LOCTITE
While holding the damper rod assembly with the
damper rod holder
2, tighten the damper rod
assembly bolt.
Damper rod holder
90890-01423, YM-01423
4. Install:

dust seal
1

oil seal clip 2

oil seal 3

washer 4
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