2004 YAMAHA YZF-R1S clutch

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.
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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
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5-60
SHIFT SHAFTENG
REMOVING THE SHIFT SHAFT
1. Remove:

left and right side cowlings

bottom cowlings
Refer to “COWLINGS” in chapter 3.
2. Remove:

clutch assembly
Refer to “CLUTCH”.
3. Remove:

shift arm

shift rod
Refer to “ENGINE”.
4. Remove:

circlip
1

Washer 2
(left side of the engine)
5. Remove:

shift shaft
1

shift shaft spring 2

collar

washer
6. Remove:

stopper lever spring
1

stopper screw 2

stopper lever 3

washer
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5-62
SHIFT SHAFTENG
4. Install:

shift rod

shift arm
Refer to “ENGINE”.
5. Install:

clutch assembly
Refer to “CLUTCH”.
6. Install:

left and side cowling

bottom cowlings
Refer to “COWLING” in chapter 3.
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5-63
Order Job / Part Q’ty Remarks
1
2
3
4
5
6
7
8Removing the oil pan and oil pump
Side cowlings
Bottom cowlings
Engine oil
Exhaust pipe and exhaust valve pipe
Clutch assembly
Water pump inlet pipe
Water pump outlet pipe
Oil level switch lead coupler
Oil level switch
Oil level switch lead holder
Oil pan
Oil pan gasket
Dowel pin
Drain pipe
Oil strainer1
1
1
1
1
2
1
1Remove the parts in the order listed.
Drain.
Refer to “CHANGING THE ENGINE OIL”
in chapter 3.
Refer to “EXHAUST PIPE”.
Refer to “CLUTCH”.
Refer to “OIL COOLER” in chapter 6.
Disconnect.
Refer to “COWLINGS” in chapter 3.
10 Nm (1.0 m
kg, 7.2 ft
lb)
10 Nm (1.0 m
kg, 7.2 ft
lb)
10 Nm (1.0 m
kg, 7.2 ft
lb)10 Nm (1.0 m
kg, 7.2 ft
lb)
12 Nm (1.2 m
kg, 8.7 ft
lb)43 Nm (4.3 m
kg, 31 ft
lb)
12 Nm (1.2 m
kg, 8.7 ft
lb)
OIL PAN AND OIL PUMPENG
EAS00356
OIL PAN AND OIL PUMP
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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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8-4
11Neutral switch
12Rear brake light switch
13Fuse box
1Main switch
2Horn switch
3Dimmer switch
4Turn signal switch
5Clutch switch
6Sidestand switch
7Engine stop switch
8Front brake light switch
9Start switch
10Oil level switch
CHECKING THE SWITCHESELEC
EAS00731
CHECKING THE SWITCHES
Check each switch for damage or wear, proper connections, and also for continuity between the termi-
nals. Refer to “CHECKING SWITCH CONTINUITY”.
Damage / wear
Repair or replace.
Improperly connected
Properly connect.
Incorrect continuity reading
Replace the switch.
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8-9
IGNITION SYSTEMELEC
1Main switch
4Fuse (main)
6Battery
10Starting circuit cut-off relay
11Neutral switch
12Sidestand switch
14E.C.U.
15Ignition coil #1
16Ignition coil #2
17Ignition coil #3
18Ignition coil #4
19Spark plug
31Crankshaft position sensor
35Cylinder identification sensor
36Lean angle cut-off switch
53Engine stop switch
59Clutch switch
73Fuse (ignition)
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