2004 YAMAHA YZF-R1S Service Manual

5-3
Order Job / Part Q’ty Remarks
11
12
13
14Muffler cover
EXUP servo motor
EXUP servo motor bracket
Protector2
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)
10 Nm (1.0 m
kg, 7.2 ft
lb)
20 Nm (2.0 m
kg, 14 ft
lb)
20 Nm (2.0 m
kg, 14 ft
lb)
20 Nm (2.0 m
kg, 14 ft
lb)
23 Nm (2.3 m
kg, 17 ft
lb)
ENGINEENG
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5-4
ENGINEENG
Order Job / Part Q’ty Remarks
Disassembling the exhaust valve
pipe
Washer
Pulley
Collar
Plate
Spring
Housing
Gasket
Shaft arm
Exhaust valve pipe
EXUP pulley bracket1
1
1
1
1
1
1
1
1
1Disassemble the parts in the order listed.
For assembly, reverse the disassembly
procedure.
1
2
3
4
5
6
7
8
9
10
10 Nm (1.0 m
kg, 7.2 ft
lb)
10 Nm (1.0 m
kg, 7.2 ft
lb)
7 Nm (0.7 m
kg, 5 ft
lb)
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5-5
Order Job / Part Q’ty Remarks
1
2Disconnecting the leads and hoses
Fuel tank
Air filter case
Throttle body assembly
Engine oil
Oil cooler
Air cut-off valve
Starter motor
Battery negative lead
Battery positive lead1
1Disconnect the parts in the order listed.
Refer to “FUEL TANK” in chapter 3.
Refer to “AIR FILTER CASE” in chapter 3.
Refer to “THROTTLE BODIES” in
chapter 7.
Drain.
Refer to “CHANGING THE ENGINE OIL”
in chapter 3.
Refer to “OIL COOLER” in chapter 6.
Refer to “AIR INDUCTION SYSTEM” in
chapter 7.
Refer to “STARTING SYSTEM” in
chapter 7.
ENGINEENG
LEADS AND HOSES
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5-6
Order Job / Part Q’ty Remarks
3
4
5
6
7
8
9
10Clutch cable
Ground lead
Stator coil assembly coupler
Crankshaft position sensor lead coupler
Oil level switch connector
Neutral switch connector
Speed sensor coupler
Cylinder identification sensor coupler1
2
1
1
1
1
1
1First, disconnect the negative battery
lead, and then the positive battery lead.
For connecting, reverse the disconnec-
tion procedure.
Disconnect.
Disconnect.
Disconnect.
Disconnect.
Disconnect.
Disconnect.
For installation, reverse the removal
procedure.
CAUTION:
ENGINEENG
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5-7
ENGINEENG
Order Job / Part Q’ty Remarks
1
2
3
4
5
6
7
8Removing the engine
Right front engine mounting bolt
Engine mount collar (inside)
Engine mount collar (outside)
Left front engine mounting bolt
Lower self locking nut
Lower engine mounting bolt
Upper self locking nut
Upper engine mounting bolt1
1
1
1
1
1
1
1Remove the parts in the order listed.
Place a suitable stand under the frame and
engine.
NOTE:
51 Nm (5.1 m
kg, 37 ft
lb)
51 Nm (5.1 m
kg, 37 ft
lb)
45 Nm (4.5 m
kg, 33 ft
lb)
7 Nm (0.7 m
kg, 5.1 ft
lb)
45 Nm (4.5 m
kg, 33 ft
lb)
ENGINE
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5-8
ENGINEENG
Order Job / Part Q’ty Remarks
9
10Engine mounting adjust bolt
Engine2
1 Use the pivot shaft wrench and adapter to
loosen the engine mounting adjust bolts.
For installation, reverse the removal pro-
cedure.
NOTE:
51 Nm (5.1 m
kg, 37 ft
lb)
51 Nm (5.1 m
kg, 37 ft
lb)
45 Nm (4.5 m
kg, 33 ft
lb)
7 Nm (0.7 m
kg, 5.1 ft
lb)
45 Nm (4.5 m
kg, 33 ft
lb)
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5-9
ENGINEENG
NOTE:
7 Nm (0.7 m
kg, 5.1 ft
lb)
NOTE: INSTALLING THE ENGINE
1. Install:

engine mounting adjust bolts
(temporary tighten)
2. Install:

engine
3. Install:

lower engine mounting bolt
1

upper engine mounting bolt 2

self locking nuts
Lubricate the lower and upper engine mounting
bolts threads with lithium-soap-based grease.
4. Install:

left front engine mount bolt
1
(temporary tighten)
5. Install:

engine mount collar (inside)
1

engine mount collar (outside) 2

right front engine mount bolt 3
(temporary tighten)
6. Tighten:

engine mounting adjust bolts
Use the pivot shaft wrench
1 and pivot shaft
wrench adapter
2 to tighten the engine mount-
ing adjust bolts.
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5-10
ENGINEENG
51 Nm (5.1 m
kg, 37 ft
lb)
NOTE:
45 Nm (4.5 m
kg, 33 ft
lb)
45 Nm (4.5 m
kg, 33 ft
lb)
Pivot shaft wrench
90890-01471, YM-01471
Pivot shaft wrench adapter
90890-01476
7. Tighten:

upper self-locking nut
1

lower self-locking nut 2
First tighten the lower self-locking nut, and then
tighten the upper self-locking nut.
8. Tighten:

left front engine mounting bolt
1
9. Tighten:

right front engine mounting bolt
1
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