2004 YAMAHA YZF-R1S Service Manual

5-67
OIL PAN AND OIL PUMPENG
EAS00364
CHECKING THE OIL PUMP
1. Check:

oil pump driven gear
1

oil pump rotor housing 2

oil pump cover
Cracks / damage / wear
Replace the de-
fective part(s).
2. Measure:

inner-rotor-to-outer-rotor-tip clearance
a

outer-rotor-to-oil-pump-housing clearance
b
1Inner rotor
2Outer rotor
3Oil pump housing
Inner-rotor-to-outer-rotor-tip
clearance
0.01
0.10 mm
(0.0004
0.0039 in)
: 0.18 mm (0.0071 in)
Outer-rotor-to-oil-pump-housing
clearance
0.09
0.15 mm
(0.0035
0.0059 in)
: 0.22 mm (0.0087 in)
3. Check:

oil pump operation
Rough movement
Repeat steps (1) and
(2) or replace the defective part(s).
EAS00365
CHECKING THE RELIEF VALVE
1. Check:

relief valve body
1

relief valve 2

spring 3

O-ring 4
Damage / wear
Replace the defective
part(s).
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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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5-69
OIL PAN AND OIL PUMPENG
NOTE:
15 Nm (1.5 m
kg, 11 ft
lb)
NOTE:
12 Nm (1.2 m
kg, 8.7 ft
lb)
2. Install:

pin
1

inner rotor 2

outer rotor 3

oil pump housing 4
When installing the inner rotor, align the pin 1 in
the oil pump shaft with the groove
a in the inner
rotor
2.
3. Install:

oil / water pump driven sprocket
1
LOCTITE
5VY mark of the oil / water pump driven gear is
installed at oil pump side.
4. Check:

oil pump operation
Refer to “CHECKING THE OIL PUMP”.
INSTALLING THE OIL / WATER PUMP
ASSEMBLY
1. Install:

O-ring
New

oil / water pump assembly
1

dowel pin

bolts
2
LOCTITE
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5-70
OIL PAN AND OIL PUMPENG
NOTE:
CAUTION:
10 Nm (1.0 m
kg, 7.2 ft
lb)
NOTE:
10 Nm (1.0 m
kg, 7.2 ft
lb)
10 Nm (1.0 m
kg, 7.2 ft
lb)
2. Install:

washer

oil / water pump assembly drive chain
1

oil / water pump assembly drive sprocket 2

collar
Install the oil / water pump assembly drive chain
1 onto the oil / water pump assembly drive
sprocket
2.
After installing the oil / water pump assem-
bly drive chain and drive sprocket, make
sure the oil / water pump turns smoothly.
3. Install:

oil / water pump assembly drive chain guide
1
LOCTITE
“UP” mark of the oil / water pump assembly drive
chain guide is upward.
4. Install:

oil delivery pipe
1
LOCTITE
5. Install:

relief valve
1

O-ring New

oil strainer
2
LOCTITE

O-ring New

oil pipe
3

O-ring New

drain pipe
4

O-ring New
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5-71
OIL PAN AND OIL PUMPENG
12 Nm (1.2 m
kg, 8.7 ft
lb)
10 Nm (1.0 m
kg, 7.2 ft
lb)
43Nm (4.3 m
kg, 31 ft
lb)
WARNING
NOTE:
EAS00380
INSTALLING THE OIL PAN
1. Install:

dowel pins

gasket
New

oil pan
1

oil level switch 2

engine oil drain bolt 3
Always use new copper washers.

Tighten the oil pan bolts in stages and in a
crisscross pattern.

Lubricate the oil level switch O-ring with en-
gine oil.
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5-72
Order Job / Part Q’ty Remarks
Removing the crankcase
Air filter case
Throttle body assembly
Engine
Cylinder head
Starter clutch and generator
Shift shaft
Crankshaft position sensor
Clutch
Oil pan and oil pump
Starter motorRemove the parts in the order listed.
Refer to “AIR FILTER CASE” in chapter 3.
Refer to “THROTTLE BODIES” in
chapter 7.
Refer to “ENGINE”.
Refer to “CYLINDER HEAD”.
Refer to “STARTER CLUTCH AND
GENERATOR”.
Refer to “SHIFT SHAFT”.
Refer to “CRANKSHAFT POSITION
SENSOR”.
Refer to “CLUTCH”.
Refer to “OIL PAN AND OIL PUMP”.
Refer to “STARTING SYSTEM” in
chapter 8.
12 Nm (1.2 m
kg, 8.7 ft
lb)12 Nm (1.2 m
kg, 8.7 ft
lb)
24 Nm (2.4 m
kg, 17 ft
lb)
10 Nm (1.0 m
kg, 7.2 ft
lb)
24 Nm (2.4 m
kg, 17 ft
lb)
12 Nm (1.2 m
kg, 8.7 ft
lb)
20 Nm (2.0 m
kg, 14 ft
lb) +60
CRANKCASEENG
CRANKCASE
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5-73
CRANKCASEENG
Order Job / Part Q’ty Remarks
1
2
3
4
5
6
7
8
9Timing chain
Timing chain guide (intake side)
Pin
Timing chain guide (exhaust side)
Left side cover
O-ring
Lower crankcase
Dowel pin
Damper1
1
2
1
1
1
1
3
1
For installation, reverse the removal
procedure.
12 Nm (1.2 m
kg, 8.7 ft
lb)12 Nm (1.2 m
kg, 8.7 ft
lb)
24 Nm (2.4 m
kg, 17 ft
lb)
10 Nm (1.0 m
kg, 7.2 ft
lb)
24 Nm (2.4 m
kg, 17 ft
lb)
12 Nm (1.2 m
kg, 8.7 ft
lb)
20 Nm (2.0 m
kg, 14 ft
lb) +60
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5-74
CRANKCASEENG
NOTE:
CAUTION:
NOTE:
EAS00384
DISASSEMBLING THE CRANKCASE
1. Place the engine upside down.
2. Remove:

crankcase bolts

Loosen each bolt 1 / 4 of a turn at a time, in
stages and in a crisscross pattern. After all of
the bolts are fully loosened, remove them.

Loosen the bolts in decreasing numerical or-
der (refer to the numbers in the illustration).

The numbers embossed on the crankcase in-
dicate the crankcase tightening sequence.
M9  105 mm (4.1 in) bolts:
1
10
M8  60 mm (2.4 in) bolt: 11 LOCTITE
M8  60 mm (2.4 in) bolts: 12, 16
M6  70 mm (2.8 in) bolts: 19, 21, 23
M6  65 mm (2.5 in) bolts: 17, 18
M6  60 mm (2.4 in) bolts: 22, 24, 25
M6  50 mm (2.0 in) bolts: 20, 26
M8  50 mm (2.0 in) bolts: 13
15
3. Remove:

lower crankcase
Tap on one side of the crankcase with a soft-
face hammer. Tap only on reinforced por-
tions of the crankcase, not on the crankcase
mating surfaces. Work slowly and carefully
and make sure the crankcase halves sepa-
rate evenly.
4. Remove:

dowel pins
5. Remove:

crankshaft journal lower bearing
(from the lower crankcase)
Identify the position of each crankshaft journal
lower bearing so that it can be reinstalled in its
original place.
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