2004 YAMAHA YZF-R1S Service Manual

4-62
STEERING HEADCHAS
Order Job / Part Q’ty Remarks
11
12
13
14
15
16
17
18
19Rubber washer
Lower ring nut
Under bracket
Bearing cover
Bearing inner race
Upper bearing
Lower bearing
Dust seal
Bearing outer race1
1
1
1
2
1
1
1
2
For assembly, reverse the disassembly
procedure.
38 Nm (0.38 m
kg, 2.75 ft
lb)113 Nm (11.3 m
kg, 82 ft
lb)
52 Nm (5.2 m
kg, 38 ft
lb)
18 Nm (1.8 m
kg, 13 ft
lb)
1st
2nd23 Nm (2.3 m
kg, 17 ft
lb)
23 Nm (2.3 m
kg, 17 ft
lb)
7 Nm (0.7 m
kg, 5.1 ft
lb)
17 Nm (1.7 m
kg, 12 ft
lb)
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4-63
STEERING HEADCHAS
WARNING
WARNING
EAS00677
REMOVING THE UNDER BRACKET
1. Stand the motorcycle on a level surface.
Securely support the motorcycle so that
there is no danger of it falling over.
2. Remove:

ring nut
1
(with the steering nut wrench 2)
Steering nut wrench
90890–01403, YU-33975
Securely support the lower bracket so that
there is no danger of it falling.
EAS00681
CHECKING THE STEERING HEAD
1. Wash:

bearings

bearing races
Recommended cleaning solvent
Kerosene
2. Check:

bearings
1

bearing races 2
Damage / pitting
Replace.
3. Replace:

bearings

bearing races
a. Remove the bearing races
1 from the steer-
ing head pipe with a long rod
2 and hammer.
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4-64
STEERING HEADCHAS
CAUTION:
NOTE:
NOTE:
NOTE: b. Remove the bearing race
3 from the lower
bracket with a floor chisel
4 and hammer.
c. Install a new rubber seal and new bearing
races.
If the bearing race is not installed properly,
the steering head pipe could be damaged.

Always replace the bearings and bearing
races as a set.

Whenever the steering head is disassembled,
replace the rubber seal.
4. Check:

upper bracket

lower bracket
(along with the steering stem)
Bends / cracks / damage
Replace.
EAS00683
INSTALLING THE STEERING HEAD
1. Lubricate:

upper bearing

lower bearing

bearing races
Recommended lubricant
Lithium-soap-based grease
2. Install:

lower ring nut
1

rubber washer 2

upper ring nut 3

lock washer 4
Refer to “CHECKING THE STEERING
HEAD” in chapter 3.
3. Install:

upper bracket

steering stem nut
Temporarily tighten the steering stem nut.
4. Install:

front fork legs
Refer to “INSTALLING THE FRONT FORK
LEGS”.
Temporarily tighten the upper and lower bracket
pinch bolts.
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4-65
Order Job / Part Q’ty Remarks
1
2
3
4
5
6
7
8
9
10Removing the rear shock absorber
assembly
EXUP servo motor
Self-locking nut / bolt
Self-locking nut / bolt
Self-locking nut / bolt
Self-locking nut
Rear shock absorber assembly
Oil seal / bearing / collar
Collar / self-locking nut / bolt
Connecting arm
Oil seal / bearing / collar
Relay arm1/1
1/1
1/1
1
1
6/3/3
1/1/1
2
2/1/1
1Remove the parts in the order listed.
Refer to “EXHAUST PIPE” in chapter 5.
For installation, reverse the removal
procedure.
92 Nm (9.2 m
kg, 67 ft
lb)44 Nm (4.4 m
kg, 32 ft
lb)
44 Nm (4.4 m
kg, 32 ft
lb)44 Nm (4.4 m
kg, 32 ft
lb)
REAR SHOCK ABSORBER ASSEMBLYCHAS
EAS00685
REAR SHOCK ABSORBER ASSEMBLY
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4-66
REAR SHOCK ABSORBER ASSEMBLYCHAS
WARNING
WARNING
EAS00687
HANDLING THE REAR SHOCK ABSORBER
AND GAS CYLINDER
This rear shock absorber and gas cylinder
contain highly compressed nitrogen gas.
Before handling the rear shock absorber or
gas cylinder, read and make sure you under-
stand the following information. The
manufacturer cannot be held responsible
for property damage or personal injury that
may result from improper handling of the
rear shock absorber and gas cylinder.

Do not tamper or attempt to open the rear
shock absorber or gas cylinder.

Do not subject the rear shock absorber or
gas cylinder to an open flame or any other
source of high heat. High heat can cause an
explosion due to excessive gas pressure.

Do not deform or damage the rear shock
absorber or gas cylinder in any way. If the
rear shock absorber, gas cylinder or both
are damaged, damping performance will
suffer.
EAS00689
DISPOSING OF A REAR SHOCK
ABSORBER AND GAS CYLINDER
Gas pressure must be released before dispos-
ing of a rear shock absorber and gas cylinder. To
release the gas pressure, drill a 2
3 mm (0.08

0.12 in) hole through the gas cylinder at a
point 15
20 mm (0.59
0.79 in) from its end
as shown.
Wear eye protection to prevent eye damage
from released gas or metal chips.
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4-67
REAR SHOCK ABSORBER ASSEMBLYCHAS
WARNING
NOTE:
NOTE:
NOTE:
EAS00690
REMOVING THE REAR SHOCK ABSORBER
ASSEMBLY
1. Stand the motorcycle on a level surface.
Becurely 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:

bottom cowling
Refer to “COWLINGS” in chapter 3.

servo motor
Refer to “EXHAUST PIPE” in chapter 5.
3. Remove:

rear shock absorber assembly lower bolt
1

relay arm-to-swingarm bolt 2
While removing the rear shock absorber as-
sembly lower bolt, hold the swingarm so that it
does not drop down.
4. Remove:

rear shock absorber assembly upper bolt
1

rear shock absorber assembly
Raise the swingarm and then remove the rear
shock absorber assembly from between the
swingarm.
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4-68
REAR SHOCK ABSORBER ASSEMBLYCHAS
NOTE:
44 Nm (4.4 m
kg, 32 ft
lb)
44 Nm (4.4 m
kg, 32 ft
lb)
44 Nm (4.4 m
kg, 32 ft
lb)
EAS00695
CHECKING THE REAR SHOCK ABSORBER
ASSEMBLY
1. Check:

rear shock absorber rod
Bends / damage
Replace the rear shock
absorber assembly.

rear shock absorber
Gas leaks / oil leaks
Replace the rear
shock absorber assembly.

spring
Damage / wear
Replace the rear shock ab-
sorber assembly.

bushings
Damage / wear
Replace.

dust seals
Damage / wear
Replace.

bolts
Bends / damage / wear
Replace.
EAS00698
INSTALLING THE REAR SHOCK
ABSORBER ASSEMBLY
1. Lubricate:

spacers

bearings
Recommended lubricant
Lithium – soap-based grease
2. Install:

rear shock absorber assembly

When installing the rear shock absorber as-
sembly, lift up the swingarm.

Install the connecting arm front bolt from the
right.
3. Tighten:

rear shock absorber assembly upper nut

rear shock absorber assembly lower nut

relay arm-to swingarm nut
4. Install :

EXUP servo motor
Refer to “EXHAUST PIPE” in chapter 5.

bottom cowling
Refer to “COWLINGS” in chapter 3.
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4-69
SWINGARM AND DRIVE CHAINCHAS
Order Job / Part Q’ty Remarks
1
2
3
4
5
6
7Removing the swingarm and drive
chain
Rear wheel
Rear shock absorber
Drive sprocket
Muffler
Catalyst pipe assembly
Right footrest bracket
Adjusting bolt / locknut
Drive chain guard
Rear fender
Brake hose holder
Pivot shaft nut / washer
Pivot shaft1
2/2
1
1
1
1/1
1Remove the parts in the order listed.
Refer to “REAR WHEEL AND BRAKE
DISC”.
Refer to “REAR SHOCK ABSORBER
ASSEMBLY”.
Refer to “ENGINE REMOVAL” in chapter
5.
Refer to “EXHAUST PIPE” in chapter 5.
Refer to “EXHAUST PIPE” in chapter 5.
28 Nm (2.8 m
kg, 20 ft
lb)
7 Nm (0.7 m
kg, 5.1 ft
lb)
7 Nm (0.7 m
kg, 5.1 ft
lb)
105 Nm (10.5 m
kg, 76 ft
lb)
2 Nm (0.2 m
kg, 1.4 ft
lb)
16 Nm (1.6 m
kg, 12 ft
lb)
EAS00700
SWINGARM AND DRIVE CHAIN
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