2004 YAMAHA YZF-R1S clutch

3-32
ADJUSTING THE CLUTCH CABLE FREE PLAY /
REPLACING THE AIR FILTER ELEMENTCHK
ADJ
a
b
NOTE: Engine side
a. Loosen the locknut
1.
b. Turn the adjusting nut
2 in direction a or b
until the specified clutch cable free play is ob-
tained.
Direction
Clutch cable free play is
increased.
DirectionClutch cable free play is
decreased.
c. Tighten the locknuts.
Lock nut
7Nm (0.7 m
kg, 5.1 ft
lb)
EAS00086
REPLACING THE AIR FILTER ELEMENT
1. Remove:

rider seat
Refer to “SEATS”.

fuel tank
Refer to “FUEL TANK”.
2. Remove:

air filter case cover
1
3. Check:

air filter element
1
Damage
Replace.
Replace the air filter element at periodic inter-
vals of 40,000 km travel.
The air filter needs more frequent service if you
are riding in unusuallu wet or dusty areas.
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4-56
Order Job / Part Q’ty Remarks
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15Removing the handlebars
Front cowling and side cowling
Left grip end
Handlebar grip
Clutch switch connector
Left handlebar switch
Clutch cable
Clutch lever
Right grip end
Throttle cable housing
Throttle cable
Throttle grip
Front brake light switch connector
Right handlebar switch
Clutch cable holder
Brake fluid reservoir tank
Brake master cylinder bracket1
1
2
1
1
1
1
1
2
1
2
1
1
1
1Remove the parts in the order listed.
Refer to “COWLINGS” in chapter 3.
Disconnect.
Disconnect.
113 Nm (11.3 m
kg, 82 ft
lb)
17 Nm (1.7 m
kg, 12 ft
lb)
11 Nm (1.1 m
kg, 8.0 ft
lb)
23 Nm (2.3 m
kg, 17 ft
lb)
13 Nm (1.3 m
kg, 9.4 ft
lb)
23 Nm (2.3 m
kg, 17 ft
lb)3.8 Nm (0.38 m
kg, 2.7 ft
lb)
3.8 Nm (0.38 m
kg, 2.7 ft
lb)
3.8 Nm (0.38 m
kg, 2.7 ft
lb)
13 Nm (1.3 m
kg, 9.4 ft
lb)
26 Nm (2.6 m
kg, 19 ft
lb)
17 Nm (1.7 m
kg, 12 ft
lb)
HANDLEBARSCHAS
EAS00665
HANDLEBARS
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4-59
HANDLEBARSCHAS
NOTE:
CAUTION:
NOTE:
NOTE:
NOTE: 2. Install:

right handlebar switch
1
Align the projection a on the right handlebar
switch with the hole
b in the right handlebar.
3. Install:

brake master cylinder holder
1

Install the brake master cylinder holder
with the “UP” mark facing up.

First, tighten the upper bolt, then the lower
bolt.

Align the mating surfaces of the brake master
cylinder holder with the punch mark
a in the
right handlebar.

There should be 2 mm (0.08 in) of clearance
between the right handlebar switch and the
brake master cylinder holder.
4. Install:

throttle grip

throttle cable housing
1

throttle cables
Align the projection
a on the throttle cable
housing with the hole
b in the right handlebar.
5. Install:

clutch lever holder
1
Align the slit in the clutch lever holder with the
punch mark
a in the left handlebar.
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4-60
HANDLEBARSCHAS
NOTE:
WARNING
6. Install:

left handlebar switch
1
Align the projection a on the left handlebar
switch with the hole
b in the left handlebar.
7. Install:

handlebar grip
a. Apply a thin coat of rubber adhesive onto the
end of the left handlebar.
b. Slide the handlebar grip over the end of the
left handlebar.
c. Wipe off any excess rubber adhesive with a
clean rag.
Do not touch the handlebar grip until the
rubber adhesive has fully dried.
8. Adjust:

clutch cable free play
Refer to “ADJUSTING THE CLUTCH
CABLE FREE PLAY” in chapter 3.
Clutch cable free play
(at the end of the clutch lever)
10
15 mm (0.39
0.59 in)
9. Adjust:

throttle cable free play
Refer to “ADJUSTING THE THROTTLE
CABLE FREE PLAY” in chapter 3.
Throttle cable free play
(at the flange of the throttle grip)
3
5 mm (0.12
0.20 in)
CHECKING THE STEERING DAMPER
1. Check:

steering damper body
Damage / oil leaks
Replace.
(It replace with the assembly.)

steering damper rod
Bends / scratch
Replace.
(It replace with the assembly.)

bearing
Damage /pitting
Replace.
(It replace with the assembly.)
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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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5-35
Order Job / Part Q’ty Remarks
1
2
3
4
5
6
7
8
9Removing the stator coil assembly
Rider seat
Fuel tank
Left side cowling
Bottom cowlings
Engine oil
Stator coil assembly lead coupler
Plug
Generator rotor cover
Gasket
Dowel pin
Generator rotor assembly
Dowel pin
Bearing housing
Collar1
1
1
1
2
1
2
1
1Remove the parts in the order listed.
Refer to “SEATS” in chapter 3.
Refer to “FUEL TANK” in chapter 3.
Refer to “COWLINGS” in chapter 3.
Drain.
Refer to “CHANGING THE ENGINE OIL”
in chapter 3.
Disconnect.
10 Nm (1.0 m
kg, 7.2 ft
lb)
12 Nm (1.2 m
kg, 8.7 ft
lb)
12 Nm (1.2 m
kg, 8.7 ft
lb)
12 Nm (1.2 m
kg, 8.7 ft
lb)
10 Nm (1.0 m
kg, 7.2 ft
lb)
10 Nm (1.0 m
kg, 7.2 ft
lb)
14 Nm (1.4 m
kg, 10 ft
lb)
22 Nm (2.2 m
kg, 16 ft
lb)
22 Nm (2.2 m
kg, 16 ft
lb)
STARTER CLUTCH AND GENERATORENG
STARTER CLUTCH AND GENERATOR
STATOR COIL ASSEMBLY
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5-36
STARTER CLUTCH AND GENERATORENG
Order Job / Part Q’ty Remarks
10
11
12
13
14
15Bearing
Stator coil assembly lead holder
Idler gear
Idler gear shaft
Washer
Bearing1
1
1
1
1
1
For installation, reverse the removal
procedure.
10 Nm (1.0 m
kg, 7.2 ft
lb)
12 Nm (1.2 m
kg, 8.7 ft
lb)
12 Nm (1.2 m
kg, 8.7 ft
lb)
12 Nm (1.2 m
kg, 8.7 ft
lb)
10 Nm (1.0 m
kg, 7.2 ft
lb)
10 Nm (1.0 m
kg, 7.2 ft
lb)
14 Nm (1.4 m
kg, 10 ft
lb)
22 Nm (2.2 m
kg, 16 ft
lb)
22 Nm (2.2 m
kg, 16 ft
lb)
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5-37
Order Job / Part Q’ty Remarks
1
2
3
4
5
6
7
8
9Removing the starter clutch
Generator rotor
Damper
Driven gear
Washer
Starter clutch drive gear
Collar
Washer
Spacer
O-ring1
3
1
1
1
1
1
1
1Remove the parts in the order listed.
For installation, reverse the removal
procedure.
STARTER CLUTCH AND GENERATORENG
STARTER CLUTCH
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