YAMAHA YZF-R1S 2004 Service Manual

3-34
CHECKING THE FUEL AND BREATHER HOSES /
CHECKING THE CRANKCASE BREATHER HOSECHK
ADJ
CAUTION:
CAUTION:
CAUTION:
3. Install:

fuel tank
Refer to “FUEL TANK”.

rider seat
Refer to “SEATS”.
To install the fuel tank, check that the breath-
er hose is not folded or pinched by the fuel
tank.
EAS00098
CHECKING THE CRANKCASE BREATHER
HOSE
1. Remove:

rider seat
Refer to “SEATS”.

fuel tank
Refer to “FUEL TANK”.
2. Check:

crankcase breather hose
1
Cracks / damage
Replace.
Loose connection
Connect properly.
Make sure the crankcase breather hose is
routed correctly.
3. Install:

fuel tank
Refer to “FUEL TANK”.

rider seat
Refer to “SEATS”.
To install the fuel tank, check that the breath-
er hose is not folded or pinched by the fuel
tank.
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3-35
CHECKING THE EXHAUST SYSTEM
CHK
ADJ
WARNING
NOTE:
EAS00099
CHECKING THE EXHAUST SYSTEM
The following procedure applies to all of the ex-
haust pipes and gaskets.
Do not touch the muffler bracket until the ex-
haust system has cooled.
1. Check:

exhaust pipe
1

exhaust valve pipe 2

muffler 3
Cracks / damage
Replace.

gaskets
4
Exhaust gas leaks
Replace.
2. Check:

tightening torque
Exhaust pipe nut
5
20 Nm (2.0 m
kg, 14 ft
lb)
Exhaust pipe and exhaust valve
pipe bolt
6
10 Nm (1.0 m
kg, 7.2 ft
lb)
Catalyst pipe assembly bolt
7
20 Nm (2.0m
kg, 14 ft
lb)
Catalyst pipe assembly and
muffler bolt
8
20 Nm (2.0 m
kg, 14 ft
lb)
Muffler cover
9
10 Nm (1.0 m
kg, 7.2 ft
lb)
Install the EXUP cable in parallel without twist-
ing its upper
10 and lower sides 11.

black metal
10 is upper.

white metal
11 is lower.
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3-36
ADJUSTING THE EXUP CABLES
CHK
ADJ
EAS00101
ADJUSTING THE EXUP CABLES
1. Remove:

bottom cowlings
Refer to “COWLINGS”.
2. Remove:

EXUP valve pulley cover
1
3. Check:

EXUP system operation
a. Turn the main switch ON.
b. Check that the EXUP valve operates properly.
4. Check:

EXUP cable free play (at the EXUP valve
pulley)
a + b
Maximum EXUP cable free play
(at the EXUP valve pulley)
Less than 4 mm (0.16 in)
5. Adjust:

EXUP cable free play
a. Turn the main switch to “ON”.
b. Check the EXUP pulley position.
c. Projection of the EXUP pulley position is be-
tween
1 and 2.
d. Loosen the both locknuts
3.
e. Turn the both adjusting nuts
4 in or out.
f. Tighten the both locknuts.
6. Install:

EXUP valve pulley cover
EXUP valve pulley cover bolt
10 Nm (1.0 m
kg, 7.2 ft
lb)
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3-37
ADJUSTING THE EXUP CABLES /
CHECKING THE COOLANT LEVELCHK
ADJ
NOTE:
CAUTION:
NOTE: 7. Install:

bottom cowlings
Refer to “COWLINGS”.
EAS00102
CHECKING THE COOLANT LEVEL
1. Stand the motorcycle on a level surface.

Place the motorcycle on a suitable stand.

Make sure the motorcycle is upright.
2. Check:

coolant level
The coolant level should be between the
maximum level mark
a and minimum level
mark
b.
Below the minimum level mark
Add the
recommended coolant to the proper level.

Adding water instead of coolant lowers the
antifreeze content of the coolant. If water is
used instead of coolant check, and if nec-
essary, correct the antifreeze concentra-
tion of the coolant.

Use only distilled water. However, if dis-
tilled water is not available, soft water may
be used.
3. Start the engine, warm it up for several min-
utes, and then turn it off.
4. Check:

coolant level
Before checking the coolant level, wait a few
minutes until it settles.
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3-38
CHECKING THE COOLING SYSTEM
CHK
ADJ
EAS00104
CHECKING THE COOLING SYSTEM
1. Remove:

bottom cowlings

side cowlings
Refer to “COWLINGS”.
2. Check:

radiator
1

radiator inlet hose 2

radiator outlet hose 3

oil cooler 4

oil cooler inlet hose 5

oil cooler outlet hose 6

water jacket joint 7

water jacket joint inlet hose 8

water pump inlet pipe 9

water pump outlet pipe 10
Cracks / damage
Replace.
Refer to “COOLING SYSTEM” in chapter 6.
3. Install:

side cowlings

bottom cowling
Refer to “COWLINGS”.
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3-39
CHANGING THE COOLANT
CHK
ADJ
CAUTION:
EAS00105
CHANGING THE COOLANT
1. Remove:

bottom cowlings

side cowlings
Refer to “COWLINGS”.

rider seat
Refer to “SEATS”.
2. Remove:

coolant reservoir tank

coolant reservoir hose
3. Disconnect:

coolant reservoir cap
1
4. Drain:

coolant
(from the coolant reservoir tank)
5. Remove:

radiator cap
1
A hot radiator is under pressure. Therefore,
do not remove the radiator cap when the en-
gine is hot. Scalding hot fluid and steam may
be blown out, which could cause serious in-
jury. When the engine has cooled, open the
radiator cap as follows:
Place a thick rag or a towel over the radiator
cap and slowly turn the radiator cap coun-
terclockwise toward the detent to allow any
residual pressure to escape. When the his-
sing sound has stopped, press down on the
radiator cap and turn it counterclockwise to
remove.
The following procedure applies to all of the
coolant drain bolts and copper washers.
6. Remove:

coolant drain bolts
1
(along with the copper washers)
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3-40
CHANGING THE COOLANT
CHK
ADJ
10 Nm (1.0 m
kg, 7.2 ft
lb)
WARNING
7. Drain:

coolant
(water pump inlet pipe and outlet pipe)
8. Check:

copper washers
1 New
9. Install:

coolant drain bolts
2
(with copper washers)
10. Install:

coolant reservoir tank
11. Connect:

coolant reservoir hose
12. Fill:

cooling system
(with the specified amount of the recom-
mended coolant)
Recommended antifreeze
High-quality ethylene glycol
antifreeze containing corrosion
inhibitors for aluminum engines
Mixing ratio
1:1 (antifreeze:water)
Quantity
Total amount
2.51 L
(2.21 Imp qt, 2.65 US qt)
Coolant reservoir capacity
0.25 L
(0.22 Imp qt, 0.26 US qt)
Handling notes for coolant
Coolant is potentially harmful and should be
handled with special care.

If coolant splashes in your eyes, thorough-
ly wash them with water and consult a doc-
tor.

If coolant splashes on your clothes, quick-
ly wash it away with water and then with
soap and water.

If coolant is swallowed, induce vomiting
and get immediate medical attention.
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3-41
CHANGING THE COOLANT
CHK
ADJ
CAUTION:
NOTE:
Adding water instead of coolant lowers the
antifreeze content of the coolant. If water is
used instead of coolant check, and if nec-
essary, correct the antifreeze concentra-
tion of the coolant.

Use only distilled water. However, if dis-
tilled water is not available, soft water may
be used.

If coolant comes into contact with painted
surfaces, immediately wash them with wa-
ter.

Do not mix different types of antifreeze.
13. Install:

radiator cap
14. Fill:

coolant reservoir tank
(with the recommended coolant to the maxi-
mum level mark
a)
15. Install:

coolant reservoir cap
16. Start the engine, warm it up for several min-
utes, and then stop it.
17. Check:

coolant level
Refer to “CHECKING THE COOLANT LEV-
EL”.
Before checking the coolant level, wait a few
minutes until the coolant has settled.
18. Install:

rider seat
Refer to “SEATS”.

bottom cowlings

side cowlings
Refer to “COWLINGS”.
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3-42
ADJUSTING THE FRONT BRAKE
CHK
ADJ
NOTE:
a
ac
b
WARNING
CAUTION:
EAS00107
CHASSIS
ADJUSTING THE FRONT BRAKE
1. Adjust:

brake lever position
(distance
a from the throttle grip to the brake
lever)
While pushing the brake lever forward, turn the
adjusting dial
1 until the brake lever is in the de-
sired position.
Direction
Distance is the
largest.
DirectionDistance is the
smallest.

After adjusting the brake lever position,
make sure the pin on the brake lever holder
is firmly inserted in the hole in the adjust-
ing dial.

A soft or spongy feeling in the brake lever
can indicate the presence of air in the brake
system. Before the vehicle is operated, the
air must be removed by bleeding the brake
system. Air in the brake system will consid-
erably reduce in loss of control and possi-
bly an accident. Therefore, check and if
necessary, bleed the brake system.
After adjusting the brake lever position,
make sure there is no brake drag.
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3-43
ADJUSTING THE REAR BRAKE
CHK
ADJ
a
b
WARNING
WARNING
CAUTION:
EAS00110
ADJUSTING THE REAR BRAKE
1. Adjust:

brake pedal position
a. Loosen the locknut
1.
b. Turn the adjusting bolt
2 in direction a or b
until the specified brake pedal position is ob-
tained.
Direction
Brake pedal is raised.
DirectionBrake pedal is lowered.
After adjusting the brake pedal position,
check that the end of the adjusting bolt
c is
visible through the hole
d.
c. Tighten the locknut
1 to specification.
Locknut
16 Nm (1.6 m
kg, 12 ft
lb)
A soft or spongy feeling in the brake pedal
can indicate the presence of air in the brake
system. Before the vehicle is operated, the
air must be removed by bleeding the brake
system. Air in the brake system will consid-
erably reduce braking performance and
could result in loss of control and possibly
an accident. Therefore, check and, if neces-
sary, bleed the brake system.
After adjusting the brake pedal position,
make sure there is no brake drag.
2. Adjust:

rear brake light switch
Refer to “ADJUSTING THE REAR BRAKE
LIGHT SWITCH”.
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