2004 YAMAHA YZF-R1S transmission

5-101
Order Job / Part Q’ty Remarks
Disassembling the drive axle
assembly
Washer
1st wheel gear
Collar
5th wheel gear
Circlip
Washer
3rd wheel gear
Collar
Toothed lock washer
Toothed lock washer retainer
4th wheel gear
Collar
Washer
Circlip1
1
1
1
1
1
1
1
1
1
1
1
1
1Disassemble the parts in the order listed.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
TRANSMISSIONENG
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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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5-104
TRANSMISSIONENG
WARNING
2. Check:

shift fork guide bar
Roll the shift fork guide bar on a flat surface.
Bends
Replace.
Do not attempt to straighten a bent shift fork
guide bar.
3. Check:

shift fork movement
(along the shift fork guide bar)
Rough movement
Replace the shift forks
and shift fork guide bar as a set.
EAS00422
CHECKING THE SHIFT DRUM ASSEMBLY
1. Check:

shift drum grooves
1
Damage / scratches / wear
Replace the
shift drum assembly.

shift drum segment
2
Damage / wear
Replace the shift drum as-
sembly.

shift drum bearing
3
Damage / pitting
Replace the shift drum
assembly.
EAS00425
CHECKING THE TRANSMISSION
1. Measure:

main axle runout
(with a centering device and dial gauge
1)
Out of specification
Replace the main
axle.
Main axle runout limit
0.08 mm (0.0032 in)
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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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7-22
FUEL INJECTION SYSTEMFI
Fault code No.19SymptomOpen circuit in the input line of ECU No.15 terminal is detected.
Used diagnostic code No. 20 (sidestand switch)
OrderInspection operation item and probable
causeOperation item and countermeasureReinstatement
method
1Connected condition of connector
Main wiring harness ECU coupler
(No.15 pin)
Execute the diagnostic mode (Code No.20).
Check the coupler for any pins that may have
pulled out.
Check the locking condition of the coupler.
If there is a malfunction, repair it and connected it
securely.If the
transmission is
in gear, it is
reinstated by
retracting the
sidestand.
If the
2Open or short circuit in wiring harness
and / or sub lead.Repair or replace if there is an open or short
circuit.
Between sidestand switch coupler and ECU
coupler
Blue / Black – Blacktransmission is
in neutral, it is
reinstated by
reconnecting
the wiring.
3The malfunction of the sidestand switch.Replace if defective.
Refer to “CHECKING THE SWITCHES” in
chapter 8.
Fault code No.20SymptomDefective values are detected due to the internal malfunction of the intake air
pressure sensor or the atmospheric pressure sensor.
Used diagnostic code No. 02 (atmospheric pressure sensor)
1
03 (intake air pressure sensor)
2
OrderInspection operation item and probable
causeOperation item and countermeasureReinstatement
method
1Defective atmospheric pressure sensorExecute the diagnostic mode (Code No.02).
Replace if defective.
Refer to “Fault code No.23”.Reinstated by
turning the
main switch
2Defective intake air pressure sensorExecute the diagnostic mode (Code No.03).
Replace if defective.
Refer to “Fault code No.13”.ON.
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7-29
FUEL INJECTION SYSTEMFI
Speed sensor output voltage
When sensor is on
DC 4.8 V or more
When sensor is off
DC 0.6 V or less Tester positive probe
white
Tester negative probe
black / blue
1
2
Fault code No.42Symptom1 No normal signals are received from the speed sensor.
2 Open or short circuit is detected in the neutral switch.
Used diagnostic code No. 07 (speed sensor)
A1
A4
No. 21 (neutral switch)
B1
B4
OrderInspection operation item and probable
causeOperation item and countermeasureReinstatement
method
A1Connected condition of speed sensor
connector
Inspect the coupler for any pins that
may have pulled out.
Check the locking condition of the
coupler.If there is a malfunction, repair it and connect it
securely.
Speed sensor coupler
Main wiring harness ECU couplerReinstated by
starting the
engine, and
inputting the
vehicle speed
signals by
ti thA2Open or short circuit in speed sensor
lead.Repair or replace if there is an open or short circuit.
Between sensor coupler and ECU coupler.
Blue – Blue
White / Yellow – White / Yellow
Black / Blue – Black / Blueoperating the
motorcycle at a
low speed of
20 to 30 km / h.
A3Defective speed sensorExecute the diagnostic mode (Code No.07).
Replace if defective.
1. Measure the speed sensor output voltage.
2. Connect the pocket tester (DC 20 V) to the
speed sensor coupler terminal as shown.
3. Measure the speed sensor output voltage.
4. Is the speed sensor OK?
A4Gear for detecting vehicle speed has
broken.Replace if defective.
Refer to “TRANSMISSION” in chapter 5.
OrderInspection operation item and probable
causeOperation item and countermeasureReinstatement
method.
B1Connected condition of connector
Inspect the coupler for any pins that
may have pulled out.
Check the locking condition of the
coupler.If there is a malfunction, repair it and connect it
securely.
Neutral switch connector
Main wiring harness ECU couplerReinstated by
starting the
engine, and
inputting the
vehicle speed
ilbB2Open or short circuit in neutral switch
lead.Repair or replace if there is an open or short circuit.
Between switch connector and ECU coupler
Sky blue – Black / Yellowsignals by
operating the
motorcycle at a
low speed ofB3Defective neutral switchExecute the diagnostic mode (Code No.21).
Replace if defective.
Refer to “CHECKING THE SWITCHES” in
chapter 8.low s eed of20 to 30 km / h.
B4Faulty shift drum
(neutral detection area)Replace if defective.
Refer to “TRANSMISSION” in chapter 5.
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