2004 YAMAHA YZF-R1S torque

2-24
TIGHTENING TORQUESSPEC
NOTE 1:
NOTE 2:
NOTE 3:
ItemThreadTighteningRemarksItemsizeNmm
kgft
lbRemarks
Battery box and frameM670.75.1
Atmospheric pressure sensor and battery box—0.70.070.5
Lean angle cut-off switch and battery box—20.21.4
Foot rest bracket (front) and frameM8282.820
Foot rest bracket (rear) and frameM8282.820
Rear brake master cylinder and foot rest bracketM6181.813
Rear brake hose union boltM10303.022
Sidestand bracket and frameM10636.346
Front wheel axle shaft and boltM14919.166
Rear wheel axle nutM2415015.0109
Front brake caliper and front forkM10353.525
Front brake disc and front wheelM6181.813
Rear brake disc and rear wheelM6303.022
Rear wheel sprocket and drive hubM1010010.072
Brake caliper bleed screwM860.64.3
Front wheel axle pinch boltM8202.014See NOTE 3
1. First, tighten the ring nut to approximately 52 Nm (5.2 m
kg, 38 ft
lb) with a torque wrench, then
loosen the ring nut completely.
2. Retighten the lower ring nut to specification.
Refer to “INSTALLING THE ENGINE” in chapter 5.
1. Insert the front wheel axle from the right side
and tighten it with the flange bolt from the left
side to 91 Nm (9.1 m
kg, 65.8 ft
lb).
2. In the order from the pinch bolt
2
pinch
bolt
1
pinch bolt 2, tighten each bolt to
20 Nm (2.0 m
kg, 14 ft
lb) without perform-
ing temporary tightening.
3. Check that the end face of the axle head and
the end face of the fork side are flush-
mounted. If they are out of alignment, make
sure to fit them by adding the external force
by hand or with a plastic hammer, etc.
If the end face of the axle is not parallel to the
end face of the fork, align them so that one
point of the axle circumference is positioned
on the end face of the fork.
At this stage, it can be accepted if the end
face of the axle becomes partially concave
to the end face of the fork.
4. In the order from the pinch bolt
4
pinch
bolt
3
pinch bolt 4, tighten each bolt to
20 Nm (2.0 m
kg, 14 ft
lb) without perform-
ing temporary tightening.
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3-6
FUEL TANK
CHK
ADJ
4 Nm (0.4 m
kg, 2.9 ft
lb)
NOTE:
CAUTION:
INSTALLING THE FUEL PUMP
1. Install:

fuel pump

Do not damage the installation surfaces of the
fuel tank when installing the fuel pump.

Always use a new fuel pump gasket.

Install the fuel pump as shown in the illustra-
tion.

Tighten the fuel pump bolts in stages in a criss-
cross pattern and to the specified torque.
INSTALLING THE FUEL TANK
1. Install:

fuel hose

fuel return hose

fuel hose connector cover
When installing the fuel hose, make sure
that it is securely connected, and that the
fuel hose holder is in the correct position,
otherwise the fuel hose will not be properly
installed.
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3-35
CHECKING THE EXHAUST SYSTEM
CHK
ADJ
WARNING
NOTE:
EAS00099
CHECKING THE EXHAUST SYSTEM
The following procedure applies to all of the ex-
haust pipes and gaskets.
Do not touch the muffler bracket until the ex-
haust system has cooled.
1. Check:

exhaust pipe
1

exhaust valve pipe 2

muffler 3
Cracks / damage
Replace.

gaskets
4
Exhaust gas leaks
Replace.
2. Check:

tightening torque
Exhaust pipe nut
5
20 Nm (2.0 m
kg, 14 ft
lb)
Exhaust pipe and exhaust valve
pipe bolt
6
10 Nm (1.0 m
kg, 7.2 ft
lb)
Catalyst pipe assembly bolt
7
20 Nm (2.0m
kg, 14 ft
lb)
Catalyst pipe assembly and
muffler bolt
8
20 Nm (2.0 m
kg, 14 ft
lb)
Muffler cover
9
10 Nm (1.0 m
kg, 7.2 ft
lb)
Install the EXUP cable in parallel without twist-
ing its upper
10 and lower sides 11.

black metal
10 is upper.

white metal
11 is lower.
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3-51
CHECKING AND ADJUSTING THE STEERING HEAD
CHK
ADJ
WARNING
NOTE:
NOTE:
EAS00146
CHECKING AND ADJUSTING THE
STEERING HEAD
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. Check:

steering head
Grasp the bottom of the front fork legs and
gently rock the front fork.
Binding / looseness
Adjust the steering
head.
3. Remove:

upper bracket
Refer to “HANDLEBAR” and “STEERING
HEAD” in chapter 4.
4. Adjust:

steering head
a. Remove the lock washer
1, the upper ring
nut
2, and the rubber washer 3.
b. Loosen the lower ring nut
4 and then tighten
it to specification with a steering nut wrench
5.
Set the torque wrench at a right angle to the
steering nut wrench.
Steering nut wrench
90890-01403, YU-33975
Lower ring nut (initial tightening
torque)
52 Nm (5.2 m
kg, 38 ft
lb)
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3-52
CHECKING AND ADJUSTING THE STEERING HEAD
CHK
ADJ
WARNING
NOTE:
NOTE: c. Loosen the lower ring nut
4 completely, then
tighten it to specification.
Do not overtighten the lower ring nut.
Lower ring nut
(final tightening torque)
18 Nm (1.8 m
kg, 13 ft
lb)
d. Check the steering head for looseness or
binding by turning the front fork all the way in
both directions. If any binding is felt, remove
the under bracket and check the upper and
lower bearings.
Refer to “STEERING HEAD” in chapter 4.
e. Install the rubber washer
3.
f. Install the upper ring nut
2.
g. Finger tighten the upper ring nut
2, then
align the slots of both ring nuts. If necessary,
hold the lower ring nut and tighten the upper
ring nut until their slots are aligned.
h. Install the lock washer
1.
Make sure the lock washer tabs
a sit correctly
in the ring nut slots
b.
5. Install:

upper bracket
Refer to “HANDLEBAR” and “STEERING
HEAD” in chapter 4.
6. Measure:

steering head tension
Make sure all of the cables and wires are prop-
erly routed.
a. Point the front wheel straight ahead.
b. Install a plastic locking tie
1 loosely around
the end of the handlebar as shown.
c. Hook a spring gauge
2 onto the plastic lock-
ing tie.
d. Hold the spring gauge at a 90 angle from the
handlebar, pull the spring gauge, and then
record the measurement when the handle-
bar starts to run.
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4-71
SWINGARM AND DRIVE CHAINCHAS
WARNING
NOTE:
NOTE:
EAS00703
REMOVING THE SWINGARM
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. Remove:

relay arm-to-swingarm bolt
1

connecting arm bolt 2

rear shock absorber assembly lower bolt 3
When removing the rear shock absorber as-
sembly lower bolt, hold the swingarm so that it
does not drop down.
3. Measure:

swingarm side play

swingarm vertical movement
a. Measure the tightening torque of the pivot
shaft nut.
Pivot shaft nut
105 Nm (10.5 m
kg, 76 ft
lb)
b. Measure the swingarm side play
A by mov-
ing the swingarm from side to side.
c. If the swingarm side play is out of specifica-
tion, check the spacers, bearings, washers,
and dust covers.
Swingarm side play
(at the end of the swingarm)
1.0 mm (0.04 in)
d. Check the swingarm vertical movement
B
by moving the swingarm up and down.
If swingarm vertical movement is not smooth
or if there is binding, check the spacers,
bearings, washers, and dust covers.
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5-20
CAMSHAFTENG
10 Nm (1.0 m
kg, 7.2 ft
lb)
NOTE:
CAUTION:
24 Nm (2.4 m
kg, 17 ft
lb)
CAUTION:
5. Install:

camshaft cap bolts
Tighten the camshaft cap bolts in stages and in
a crisscross pattern, working from the inner
caps out.

Lubricate the camshaft cap bolts with the
engine oil.

The camshaft cap bolts must be tightened
evenly or damage to the cylinder head,
camshaft caps, and camshafts will result.

Do not turn the crankshaft when installing
the camshaft to avoid damage or improper
valve timing.
6. Tighten:

camshaft sprocket bolts
1
Camshaft wrench
90890-04143
Be sure to tighten the camshaft sprocket
bolts to the specified torque to avoid the
possibility of the bolts coming loose and
damaging the engine.
7. Align:

camshaft punch mark
a
Align the camshaft punch mark a and the
camshaft cap arrow mark
b.
Camshaft wrench
90890-04143
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5-24
CYLINDER HEADENG
8 Nm (0.8 m
kg, 5.8 ft
lb)
NOTE:
NOTE:
19 Nm (1.9 m
kg, 14 ft
lb)
67 Nm (6.7 m
kg, 48 ft
lb)
12 Nm (1.2 m
kg, 8.7 ft
lb)
NOTE:
EAS00233
INSTALLING THE CYLINDER HEAD
1. Check:

cylinder head bolts
1
Retighten the cylinder head bolts to specifica-
tion, before installing the cylinder head.
2. Install:

gasket
New
1

dowel pins
3. Install:

cylinder head
Pass the timing chain through the timing chain
cavity.
4. Tighten:

cylinder head nuts
1
10
1st
2nd

cylinder head bolts
11 12

First, tighten the nuts 1
10 to approximate-
ly 19 Nm (1.9 m
kg, 14 ft
lb) with a torque
wrench, and then tighten the 67 Nm (6.7 m
kg,
48 ft
lb).

Lubricate the cylinder head nuts with engine
oil.

Tighten the cylinder head nuts in the proper
tightening sequence as shown and torque
them in two stages.
5. Install:

exhaust camshaft

intake camshaft
Refer to “INSTALLING THE CAMSHAFTS”.
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