2004 YAMAHA YZF-R1S recommended oil

4-53
FRONT FORKCHAS
NOTE:
NOTE: 8. Install:

rod puller
1

rod puller attachment 2
(onto the damper rod 3)
Rod puller
90890-01437, YM-01437
Rod puller attachment
90890-01436, YM-01436
9. Fill:

front fork leg
(with the specified amount of the recom-
mended fork oil)
Quantity (each front fork leg)
0.53 L (0.47 Imp qt, 0.56 US qt)
Recommended oil
Suspension oil “01” or
equivalent
Front fork leg oil level (from the
top of the outer tube, with the
outer tube fully compressed and
without the fork spring)
76 mm (2.99 in)

While filling the front fork leg, keep it upright.

After filling, slowly pump the front fork leg up
and down to distribute the fork oil.
10. Install:

nut
1

fork spring 2

spacer 3

damper adjusting rod 4

cap bolt 5
a. Remove the rod puller and adapter.
b. Install the nut.
c. Install the fork spring, and spacer.
Install the spring with the smaller pitch
a facing
up
A.
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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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4-73
SWINGARM AND DRIVE CHAINCHAS
NOTE: 3. Wash:

pivot shaft

dust covers

spacer

washers

bearings
Recommended cleaning solvent
Kerosene
4. Check:

dust covers
1

spacer 2
Damage / wear
Replace.

bearings
3
Damage / pitting
Replace.
5. Check:

connecting arms
1

relay arm 2
Damage / wear
Replace.
6. Check:

bearings
3

oil seals 4
Damage / pitting
Replace.
7. Check:

collars
5
Damage / scratches
Replace.
EAS00709
CHECKING THE DRIVE CHAIN
1. Measure:

ten-link section
a of the drive chain
Out of specification
Replace the drive
chain.
Ten-link drive chain section limit
(maximum)
150.1 mm (5.91 in)

While measuring the ten-link section, push
down on the drive chain to increase its tension.

Measure the length between drive chain roller
1 and 11 as shown.

Perform this measurement at two or three dif-
ferent places.
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4-74
SWINGARM AND DRIVE CHAINCHAS
CAUTION:
2. Check:

drive chain
Stiffness
Clean and lubricate or replace.
3. Clean:

drive chain
a. Wipe the drive chain with a clean cloth.
b. Put the drive chain in kerosene and remove
any remaining dirt.
c. Remove the drive chain from the kerosene
and completely dry it.
This motorcycle has a drive chain with small
rubber O-rings
1 between the drive chain
side plates. Never use high-pressure water
or air, steam, gasoline, certain solvents
(e.g., benzine), or a coarse brush to clean the
drive chain. High-pressure methods could
force dirt or water into the drive chain’s in-
ternals, and solvents will deteriorate the O-
rings. A coarse brush can also damage the
O-rings. Therefore, use only kerosene to
clean the drive chain. Don’t soak drive chain
in kerosine more them ten minutes. O-ring is
damage by kerosine.
4. Check:

O-rings
1
Damage
Replace the drive chain.

drive chain rollers
2
Damage / wear
Replace the drive chain.

drive chain side plates
3
Damage / wear
Replace the drive chain.
Cracks
Replace the drive chain and make
sure the battery breather hose is properly
routed away from the drive chain and below
the swingarm.
5. Lubricate:

drive chain
Recommended lubricant
Engine oil or chain lubricant
suitable for O-ring chains
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5-33
VALVES AND VALVE SPRINGSENG
NOTE:
NOTE:
NOTE:
2. Lubricate:

valve stem
1

valve stem seal 2
(with the recommended lubricant)
Recommended lubricant
Molybdenum disulfide oil
3. Install:

valve
1

lower spring seat 2

valve stem seal 3

valve spring 4

upper spring seat 5
(into the cylinder head)
Install the valve spring with the larger pitch
a
facing up.
bSmaller pitch
Make sure that each valve is installed in its origi-
nal place. Refer to the following embossed
marks.
Right and left intake valve(-s): “5VY :”
Middle intake valve(-s): “5VY
.”
Exhaust valve(-s): “5VY”
4. Install:

valve cotters
1
Install the valve cotters by compressing the
valve spring with the valve spring compressor
2 and the valve spring compressor attachment
3.
Valve spring compressor
90890-04019, YM-04019
Valve spring compressor
attachment
Intake valve
90890-04114, YM-4114
Exhaust valve
90890-04108, YM-4108
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5-56
CLUTCHENG
NOTE:
10 Nm (1.0 m
kg, 7.2 ft
lb)
NOTE:
NOTE: 6. Lubricate:

friction plates

clutch plates
(with the recommended lubricant)
Recommended lubricant
Engine oil
7. Install:

friction plate 2

clutch plate 1
1
8. Install:

friction plate 1
1
Install the last friction plate shifting half phase.
9. Install:

bearing

pull rod
1

pressure plate 2

clutch springs

clutch spring bolts
3
Tighten the clutch spring bolts in stages and in a
crisscross pattern.
10. Install:

pull lever
In stall the pull lever with the “” mark facing to-
ward upper side.
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5-68
OIL PAN AND OIL PUMPENG
EAS00367
CHECKING THE OIL DELIVERY PIPE AND
OIL PIPE
1. Check:

oil delivery pipe
1

oil pipe 2
Damage
Replace.
Obstruction
Wash and blow out with com-
pressed air.
EAS00368
CHECKING THE OIL STRAINER
1. Check:

oil strainer
1
Damage
Replace.
Contaminants
Clean with solvent.
EAS00373
CHECKING THE OIL NOZZLES
The following procedure applies to all of the oil
nozzles.
1. Check:

oil nozzle
1
Damage / wear
Replace the oil nozzle.

O-ring
2
Damage / wear
Replace.

oil nozzle passage
Obstruction
Blow out with compressed air.
EAS00374
ASSEMBLING THE OIL PUMP
1. Lubricate:

inner rotor

outer rotor

oil pump shaft
(with the recommended lubricant)
Recommended lubricant
Engine oil
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5-75
CRANKCASEENG
NOTE:
EAS00399
CHECKING THE CRANKCASE
1. Thoroughly wash the crankcase halves in a
mild solvent.
2. Thoroughly clean all the gasket surfaces and
crankcase mating surfaces.
3. Check:

crankcase
Cracks / damage
Replace.

oil delivery passages
Obstruction
Blow out with compressed air.
EAS00401
CHECKING THE BEARINGS AND OIL
SEALS
1. Check:

bearings
Clean and lubricate the bearings, then rotate
the inner race with your finger.
Rough movement
Replace.
2. Check:

oil seals
Damage / wear
Replace.
ASSEMBLING THE CRANKCASE
1. Lubricate:

crankshaft journal bearings
(with the recommended lubricant)
Recommended lubricant
Engine oil
2. Apply:

sealant
Yamaha bond No. 1215
90890-85505, ACC-1109-05-01
Do not allow any sealant to come into contact
with the oil gallery or crankshaft journal bear-
ings. Do not apply sealant to within 2
3 mm
(0.08
0.12 in) of the crankshaft journal bear-
ings.
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