clock YAMAHA YZF-R1S 2004 User Guide

5-19
CAMSHAFTENG
NOTE:
NOTE:
NOTE:
EAS00215
INSTALLING THE CAMSHAFTS
1. Align:

“T” mark
a on the pickup rotor
(with the crankcase mating surface
b)
a. Turn the crankshaft clockwise.
b. When piston #1 is at TDC, align the “T” mark
a with the crankcase mating surface b.
2. Install:

intake camshaft sprocket
1

exhaust camshaft sprocket 2
(with the camshaft sprockets temporarily
tightened)
Install the camshaft sprockets as a illustration.
3. Install:

exhaust camshaft
1

intake camshaft 2
(with the camshaft sprockets temporarily
tightened)
Make sure the punch mark
a faces up.
4. Install:

dowel pins

exhaust camshaft caps

intake camshaft caps

Make sure each camshaft cap is installed in its
original place.

Make sure the arrow mark
a on each cam-
shaft cap points towards the right side of the
engine.
L: Left side camshaft cap mark
R: Right side camshaft cap mark
I: Intake side camshaft cap mark
E: Exhaust side camshaft cap mark
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5-21
CAMSHAFTENG
10 Nm (1.0 m
kg, 7.2 ft
lb)
CAUTION:
WARNING
8. Install:

O-ring
New

timing chain tensioner
1

timing chain tensioner bolts 2
The “arrow” mark a on the timing chain ten-
sioner should face up.
Always use a new O-ring.
9. Turn:

crankshaft
(several full turns clockwise)
10. Check:

“T” mark
a
Make sure the “T” mark on the pickup rotor is
aligned with the crankcase mating sure face
b.

camshaft punch mark
c
Make sure the punch mark c on the cam-
shaft is aligned with the camshaft cap arrow
mark
d.
Out of alignment
Adjust.
Refer to the installation steps above.
11. Measure:

valve clearance
Out of specification
Adjust.
Refer to “ADJUSTING THE VALVE CLEAR-
ANCE” in chapter 3.
12. Install:

pickup coil rotor cover
Refer to “CRANKSHAFT POSITION SEN-
SOR”.
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5-40
STARTER CLUTCH AND GENERATORENG
EAS00351
CHECKING THE STARTER CLUTCH
1. Check:

starter clutch rollers
1
Damage / wear
Replace.
2. Check:

starter clutch idle gear
1

starter clutch drive gear 2
Burrs / chips / roughness / wear
Replace
the defective part(s).
3. Check:

starter clutch gear’s contacting surfaces
a
Damage / pitting / wear
Replace the starter
clutch gear.
4. Check:

starter clutch operation
a. Install the starter clutch drive gear
1 onto
the starter clutch
2 and hold the starter
clutch.
b. When turning the starter clutch drive gear
counterclockwise
A, the starter clutch and
the starter clutch drive gear should engage,
otherwise the starter clutch is faulty and must
be replaced.
c. When turning the starter clutch drive gear
clockwise
B, it should turn freely, otherwise
the starter clutch is faulty and must be re-
placed.
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7-8
FUEL INJECTION SYSTEMFI
NOTE:
NOTE:
EAS00905
DIAGNOSTIC MODE
It is possible to monitor the sensor output data
or check the activation of actuators without con-
necting the measurement equipment by simply
switching the meter indication from the normal
mode to the diagnostic monitoring mode.
Setting the diagnostic mode
1. Turn the main switch to “OFF” and set the en-
gine stop switch to “OFF”.
2. Disconnect the wire harness coupler from
the fuel pump.
3. Simultaneously press and hold the “SE-
LECT” and “RESET” buttons, turn the main
switch to “ON”, and continue to press the but-
tons for 8 seconds or more.

All displays on the meter disappear except the
clock and tripmeter displays.

“dIAG” appears on the LCD meter.
4. Press the “SELECT” button to select the CO
adjustment mode “Co” or the diagnostic
mode “dIAG”.
5. After selecting “dIAG”, simultaneously press
the “SELECT” and “RESET” buttons for 2 se-
conds or more to execute the selection.
6. Select the diagnostic code number that ap-
plies to the item that was verified with the
fault code number by pressing the “SELECT”
and “RESET” buttons.

The diagnostic code number appears on the
LCD meter (01-70).

To decrease the selected diagnostic code
number, press the “RESET” button. Press the
“RESET” button for 1 second or longer to auto-
matically decrease the diagnostic code num-
bers.

To increase the selected diagnostic code num-
ber, press the “SELECT” button. Press the
“SELECT” button for 1 second or longer to au-
tomatically increase the diagnostic code num-
bers.
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7-44
THROTTLE BODIESFI
2. Adjust:

sub-throttle position sensor full open angle
a. Turn the nut
1 of the worm shaft of the sub-
throttle counterclockwise until it contacts
with the full open stopper.
b. When the dimension of
a sections of the
throttle bodies #3 and #4 is measured with a
micrometer caliper, adjust with the adjuster
2 of the output shaft section of the sub-
throttle servo motor so that the dimension is
in a range from 24.2 to 24.6 mm (0.95 to 0.97
in).
AFront side
BRear side
Sub-throttle dimension a
24.2
24.6 mm (0.95
0.97 in)
c. After adjusting the dimension of
a sections
of the throttle bodies #3 and #4, measure the
dimension of
a sections of #1 and #2.
d. If the dimension of
a sections of the throttle
bodies #1 and #2 is different from the dimen-
sion of
a sections of the throttle bodies #3
and #4, adjust it to the same dimension as
the measurement value adjusted for the
throttle bodies #3 and #4, using the tuning
screw
3 located between the throttle bodies
#2 and #3.
3. Adjust:

primary opening
a. After performing the full open angle of the
sub-throttle position sensor, turn the nut of
the worm shaft clockwise, measure the di-
mension of
b section with a micrometer cali-
per or other device and adjust so that the di-
mension is in a range from 8.1 to 8.5 mm
(0.32 to 0.33 in).
AFront side
BRear side
Sub-throttle dimension b
8.1
8.5 mm (0.32
0.33 in)
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8-5
CHECKING THE BULBS AND BULB SOCKETSELEC
WARNING
EAS00732
CHECKING THE BULBS AND
BULB SOCKETS
Check each bulb and bulb socket for damage or
wear, proper connections, and also for continu-
ity between the terminals.
Damage / wear
Repair or replace the bulb,
bulb socket or both.
Improperly connected
Properly connect.
No continuity
Repair or replace the bulb, bulb
socket or both.
TYPES OF BULBS
The bulbs used on this motorcycle are shown in
the illustration on the left.

Bulbs
A and B are used for the headlights
and usually use a bulb holder that must be
detached before removing the bulb. The ma-
jority of these types of bulbs can be removed
from their respective socket by turning them
counterclockwise.

Bulbs
C are used for turn signal and
tail / brake lights and can be removed from
the socket by pushing and turning the bulb
counterclockwise.
CHECKING THE CONDITION OF THE
BULBS
The following procedure applies to all of the
bulbs.
1. Remove:

bulb

Since the headlight bulb gets extremely
hot, keep flammable products and your
hands away from the bulb until it has
cooled down.

When changing the tail / brake light bulb,
confirm that the frame has cooled accord-
ing to the warning label and change the
tail / brake light bulb.
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