2004 YAMAHA YZF-R1S Service Manual

5-51
CLUTCHENG
NOTE:
NOTE: 6. Loosen:

clutch boss nut
1
While holding the clutch boss 2 with the univer-
sal clutch holder
3, loosen the clutch boss nut.
Universal clutch holder
90890-04086, YM-91042
7. Remove:

clutch boss nut

washer

clutch boss assembly

thrust plate
8. Remove:

wire clip
1
There is a built-in damper between the clutch
boss and the clutch plate. It is not necessary to
remove the wire circlip
1 and disassemble the
built-in damper unless there is serious clutch
chattering.
9. Remove:

clutch plate 2
1

friction plate 3 2
10. Remove:

clutch damper spring
1

clutch damper spring seat 2
ProCarManuals.com

5-52
CLUTCHENG
NOTE:
EAS00280
CHECKING THE FRICTION PLATES
The following procedure applies to all of the fric-
tion plates.
1. Check:

friction plate
Damage / wear
Replace the friction plates
as a set.
2. Measure:

friction plate thickness
Out of specification
Replace the friction
plates as a set.
Measure the friction plate at four places.
Friction plate thickness
2.9
3.1 mm (0.114
0.122 in)
: 2.8 mm (0.110 in)
EAS00281
CHECKING THE CLUTCH PLATES
The following procedure applies to all of the
clutch plates.
1. Check:

clutch plate
Damage
Replace the clutch plates as a
set.
2. Measure:

clutch plate warpage
(with a surface plate and thickness gauge
1)
Out of specification
Replace the clutch
plates as a set.
Clutch plate warpage limit
0.1 mm (0.0039 in)
ProCarManuals.com

5-53
CLUTCHENG
NOTE:
NOTE:
EAS00282
CHECKING THE CLUTCH SPRINGS
The following procedure applies to all of the
clutch springs.
1. Check:

clutch spring
Damage
Replace the clutch springs as a
set.
2. Measure:

clutch spring free length
a
Out of specification
Replace the clutch
springs as a set.
Clutch spring free length
52.5 mm (2.07 in)
: 49.9 mm (1.96 in)
EAS00284
CHECKING THE CLUTCH HOUSING
1. Check:

clutch housing dogs
Damage / pitting / wear
Deburr the clutch
housing dogs or replace the clutch housing.
Pitting on the clutch housing dogs will cause er-
ratic clutch operation.
2. Check:

bearing
Damage / wear
Replace the bearing and
clutch housing.
EAS00285
CHECKING THE CLUTCH BOSS
1. Check:

clutch boss splines
Damage / pitting / wear
Replace the clutch
boss.
Pitting on the clutch boss splines will cause er-
ratic clutch operation.
ProCarManuals.com

5-54
CLUTCHENG
NOTE:
EAS00286
CHECKING THE PRESSURE PLATE
1. Check:

pressure plate
1
Cracks / damage
Replace.

bearing
2
Damage / wear
Replace.
EAS00287
CHECKING THE PULL LEVER SHAFT AND
PULL ROD
1. Check:

pull lever shaft pinion gear teeth
1

pull rod teeth 2
Damage / wear
Replace the pull rod and
pull lever shaft pinion gear as a set.
2. Check:

pull rod bearing
Damage / wear
Replace.
INSTALLING THE CLUTCH
1. Install:

clutch damper spring seat
1

clutch damper spring 2
2. Install:

friction plate 3
1

clutch plate 2 2
Lubricate the engine oil.
ProCarManuals.com

5-55
CLUTCHENG
NOTE:
95 Nm(9.5 m
kg, 69 ft
lb)
NOTE:
3. Install:

wire clip
1
4. Install:

clutch housing
1
Align the projection of clutch housing a and
hollow of the oil pump drive gear
b.
5. Install:

thrust plate

clutch boss assembly
1

washer

clutch boss nut
2 New

Install the washer on the main axle with the
“OUT” mark facing away from the motorcycle.

Lock the threads on the clutch boss nut by
staking them with a drift punch at the point
aligned with the groove in the axle.

While holding the clutch boss assembly
1
with the clutch holding tool 3, tighten the
clutch boss nut.
Universal clutch holder
90890-04089, YM-91042
ProCarManuals.com

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.
ProCarManuals.com

5-57
CLUTCHENG
NOTE:
12 Nm (1.2 m
kg, 8.7 ft
lb)
12 Nm (1.2 m
kg, 8.7 ft
lb)
NOTE: 11. Install:

clutch cover

clutch cover gasket
New

Install the pull rod so that the teeth a face to-
wards the rear of the motorcycle. Then, install
the clutch cover.

Apply oil onto the bearing.

Apply molybdenum disulfide grease onto the
pull rod.

When installing the clutch cover, push the pull
lever and check that the punch mark
a on the
pull lever aligns with the mark
b on the clutch
cover. Make sure that the pull rod teeth and
pull lever shaft pinion gear are engaged.

Tighten the clutch cover bolts in stages and in
a crisscross pattern.
12. Tighten:

clutch cover bolts
1

clutch cover bolt 2
LOCTITE
Tighten the clutch cover bolts in a stages and in
a crisscross pattern.
13. Adjust:

clutch cable free play
Refer to “ADJUSTING THE CLUTCH
CABLE FREE PLAY” in chapter 3.
ProCarManuals.com

5-58
Order Job / Part Q’ty Remarks
1
2
3
4
5
6
7
8
9Removing the shift shaft and stopper
lever
Side cowlings
Bottom cowlings
Clutch assembly
Sift arm and shift rod
Circlip
Washer
Shift shaft
Collar
Shift shaft spring
Washer
Stopper screw
Stopper lever
Washer1
1
1
1
1
1
1
1
1Remove the parts in the order listed.
Refer to “CLUTCH”.
Refer to “ENGINE”.
Refer to “COWLINGS” in chapter 3.
22 Nm (2.2 m
kg, 16 ft
lb)
SHIFT SHAFTENG
EAS00327
SHIFT SHAFT
SHIFT SHAFT AND STOPPER LEVER
ProCarManuals.com