2004 YAMAHA YZF-R1S Service Manual

6-9
THERMOSTATCOOL
Order Job / Part Q’ty Remarks
Disassembling the thermostat
housing
Thermostat housing cover
Thermostat
Thermostat housing
O-ring1
1
1
1Disassemble the parts in the order listed.
For assembly, reverse the disassembly
procedure.
1
2
3
4
10 Nm (1.0 m
kg, 7.2 ft
lb)
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6-10
THERMOSTATCOOL
NOTE:
EAS00462
CHECKING THE THERMOSTAT
1. Check:

thermostat
Does not open at 71
85C (160
185F)

Replace.
a. Suspend the thermostat in a container filled
with water.
b. Slowly heat the water.
c. Place a thermometer in the water.
d. While stirring the water, observe the thermo-
stat and thermometer’s indicated tempera-
ture.
1Thermometer
2Water
3Thermostat
4Container
AFully closed
BFully open
If the accuracy of the thermostat is in doubt, re-
place it. A faulty thermostat could cause serious
overheating or overcooling.
2. Check:

thermostat housing cover
1

thermostat housing 2
Cracks / damage
Replace.
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6-11
THERMOSTATCOOL
10 Nm (1.0 m
kg, 7.2 ft
lb)
NOTE:
EAS00464
ASSEMBLING THE THERMOSTAT
ASSEMBLY
1. Install:

thermostat housing
1

thermostat 2

O-ring New 3

thermostat housing cover 4
Install the thermostat with its breather hole a
facing up.
EAS00466
INSTALLING THE THERMOSTAT
ASSEMBLY
1. Fill:

cooling system
(with the specified amount of the recom-
mended coolant)
Refer to “CHANGING THE COOLANT” in
chapter 3.
2. Check:

cooling system
Leaks
Repair or replace any faulty part.
3. Measure:

radiator cap opening pressure
Below the specified pressure
Replace the
radiator cap.
Refer to “CHECKING THE RADIATOR”.
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6-12
WATER PUMPCOOL
Order Job / Part Q’ty Remarks
1
2
3
4Removing the impeller shaft
Oil / water pump assembly and oil
pump rotor
Water pump cover
O-ring
Pin
Impeller shaft (along with the impeller)1
1
2
1
Remove the parts in the order listed.

The water pump and oil pump are com-
bined into one unit (oil / water pump as-
sembly).

It is not necessary to remove the impeller
shaft unless the coolant level is extreme-
ly low or coolant leaks from the oil pan.
Refer to “OIL PAN AND OIL PUMP” in
chapter 5.
12 Nm (1.2 m
kg, 8.7 ft
lb)
NOTE:
EAS00468
WATER PUMP
IMPELLER SHAFT
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6-13
WATER PUMPCOOL
Order Job / Part Q’ty Remarks
5
6
7
8Water pump seal
Oil seal
Bearing
O-ring1
1
1
1
For installation, reverse the removal
procedure.
12 Nm (1.2 m
kg, 8.7 ft
lb)
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6-14
WATER PUMPCOOL
NOTE:
NOTE:
NOTE:
EAS00471
DISASSEMBLING THE WATER PUMP
1. Remove:

water pump seal
1
Tap out the water pump seal from the inside of
the water pump housing.
2Water pump housing
2. Remove:

oil seal
1

bearing 2
Tap out the bearing and oil seal from the outside
of the water pump housing.
3Water pump housing
3. Remove:

rubber damper holder
1

rubber damper 2
(from the impeller, with a thin, flat-head
screwdriver)
Do not scratch the impeller shaft.
EAS00473
CHECKING THE WATER PUMP
1. Check:

water pump housing cover
1

water pump housing 2

impeller 3

rubber damper 4

rubber damper holder 5

water pump seals

oil seal
Cracks / damage / wear
Replace.
2. Check:

bearing
Rough movement
Replace.
3. Check:

water pump outlet pipe
Cracks / damage / wear
Replace.
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6-15
WATER PUMPCOOL
NOTE:
CAUTION:
NOTE:
NOTE:
EAS00475
ASSEMBLING THE WATER PUMP
1. Install:

oil seal
New 1
(into the water pump housing 2)

Before installing the oil seal, apply tap water or
coolant onto its out surface.

Install the oil seal with a socket that matches its
outside diameter.
2. Install:

water pump seal
New 1
Never lubricate the water pump seal surface
with oil or grease.

Install the water pump seal with the special
tools.

Before installing the water pump seal, apply
Yamaha bond No.1215 or Quick Gasket
2 to
the water pump housing
3.
Mechanical seal installer
4
90890-04078, YM-33221
Middle driven shaft bearing
driver
5
90890-04058, YM-04058
Yamaha bond #1215
90890-85505
Quick gasket
ACC-11001-05-01
APush down.
3. Install:

rubber damper
New 2

rubber damper holder New 1
Before installing the rubber damper, apply tap
water or coolant onto its outer surface.
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6-16
WATER PUMPCOOL
CAUTION:
4. Measure:

impeller shaft tilt
Out of specification
Repeat steps (3) and
(4).
Make sure the rubber damper and rubber
damper holder are flush with the impeller.
Impeller shaft tilt limit
0.15 mm (0.006 in)
1Straightedge
2Impeller
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