oil filter YAMAHA YZF-R1S 2004 User Guide

3-11
ADJUSTING THE VALVE CLEARANCE
CHK
ADJ
NOTE:
EAS00045
ENGINE
ADJUSTING THE VALVE CLEARANCE
The following procedure applies to all of the
valves.

Valve clearance adjustment should be made
on a cold engine, at room temperature.

When the valve clearance is to be measured or
adjusted, the piston must be at top dead center
(TDC) on the compression stroke.
1. Remove

rider seat
Refer to “SEATS”.

fuel tank
Refer to “FUEL TANK”.

air filter case
Refer to “AIR FILTER CASE”.

bottom cowlings

side cowlings
Refer to “COWLINGS”.

throttle body assembly
Refer to “THROTTLE BODIES” in chapter 7.

air cut-off valve
Refer to “AIR INDUCTION SYSTEM” in
chapter 7.

radiator

radiator fan motor
Refer to “RADIATOR” in chapter 6.
2. Remove

ignition coils

spark plugs

cylinder head cover

cylinder head cover gasket
Refer to “CAMSHAFT” in chapter 5.
3. Remove

pickup rotor cover
1
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3-28
CHANGING THE ENGINE OIL
CHK
ADJ
NOTE:
CAUTION:
EAS00074
CHANGING THE ENGINE OIL
1. Start the engine, warm it up for several min-
utes, and then turn it off.
2. Place a container under the engine oil drain
bolt.
3. Remove:

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

engine oil filler cap
1
Remove the engine oil filler cap 1 with the spe-
cial wrench
2 and cover 3.
5. Remove:

engine oil drain bolt
1
(along with the gasket)
6. Drain:

engine oil
(completely from the crankcase)
7. If the oil filter cartridge is also to be replaced,
perform the following procedure.
a. Remove the oil filter cartridge
1 with an oil
filter wrench
2.
Oil filter wrench
90890-01426, YU-38411
b. Lubricate the O-ring
3 of the new oil filter
cartridge with a thin coat of engine oil.
Make sure the O-ring
3 is positioned cor-
rectly in the groove of the oil filter cartridge.
c. Tighten the new oil filter cartridge to specifi-
cation with an oil filter wrench.
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3-29
CHANGING THE ENGINE OIL /
MEASURING THE ENGINE OIL PRESSURECHK
ADJ
43 Nm (4.3 m
kg, 31 ft
lb)
CAUTION:
Oil filter cartridge
17 Nm (1.7 m
kg, 12 ft
lb)
8. Replace:

engine oil drain bolt gasket
New
9. Install:

engine oil drain bolt
(along with the new gasket)
10. Fill:

crankcase
(with the specified amount of the recom-
mended engine oil)
Quantity
Total amount
3.8 L (3.35 Imp qt, 4.02 US qt)
Without oil filter cartridge
replacement
2.9 L (2.55 Imp qt, 3.07 US qt)
With oil filter cartridge
replacement
3.1 L (2.73 Imp qt, 3.28 US qt)
11. Install:

engine oil filler cap

bottom cowlings
Refer to “COWLINGS”.
12. Start the engine, warm it up for several min-
utes, and then turn it off.
EAS00077
MEASURING THE ENGINE OIL PRESSURE
1. Check:

engine oil level
Below the minimum level mark
a
Add the
recommended engine oil to the proper level.
2. Start the engine, warm it up for several min-
utes, and then turn it off.
When the engine is cold, the engine oil will
have a higher viscosity, causing the engine
oil pressure to increase. Therefore, be sure
to measure the engine oil pressure after
warming up the engine.
3. Remove:

bottom cowlings
Refer to “COWLINGS”.
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3-31
MEASURING THE ENGINE OIL PRESSURE /
ADJUSTING THE CLUTCH CABLE FREE PLAYCHK
ADJ
8 Nm (0.8 m
kg, 5.8 ft
lb)
CAUTION:
c
b
NOTE:Engine oil pressure
Possible causes
Below
ifi i
Faulty oil pump
specificationClogged oil filter
Leaking oil
passage
Broken or
damaged oil seal
Above
specificationLeaking oil
passage
Faulty oil filter
Oil viscosity too
high
7. Install:

oil gallery bolt
1
Be carful to tighten too much.
8. Install:

bottom cowlings
Refer to “COWLINGS”.
EAS00078
ADJUSTING THE CLUTCH CABLE FREE
PLAY
1. Check:

clutch cable free play
a
Out of specification
Adjust.
Clutch cable free play (at the
end of the clutch lever)
10  15 mm (0.39  0.59 in)
2. Adjust:

clutch cable free play
Handlebar side
a. Turn the adjusting dial
1 in direction b or c
until the specified clutch cable free play is ob-
tained.
Direction
Clutch cable free play is
increased.
DirectionClutch cable free play is
decreased.
If the specified clutch cable free play cannot be
obtained on the handlebar side of the cable, use
the adjusting nut on the engine side.
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5-5
Order Job / Part Q’ty Remarks
1
2Disconnecting the leads and hoses
Fuel tank
Air filter case
Throttle body assembly
Engine oil
Oil cooler
Air cut-off valve
Starter motor
Battery negative lead
Battery positive lead1
1Disconnect the parts in the order listed.
Refer to “FUEL TANK” in chapter 3.
Refer to “AIR FILTER CASE” in chapter 3.
Refer to “THROTTLE BODIES” in
chapter 7.
Drain.
Refer to “CHANGING THE ENGINE OIL”
in chapter 3.
Refer to “OIL COOLER” in chapter 6.
Refer to “AIR INDUCTION SYSTEM” in
chapter 7.
Refer to “STARTING SYSTEM” in
chapter 7.
ENGINEENG
LEADS AND HOSES
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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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7-1
FUEL INJECTION SYSTEMFI
19Atmospheric pressure
sensor
20Fuel injection system
relay
21Engine trouble warning
light
22Lean angle cut-off
switch
23Air cut-off valve
13Coolant temperature
sensor
14Spark plug
15Cylinder identification
sensor
16Pressure regulator
17Battery
18ECU
1Ignition coil
2Air filter case
3Intake temperature
sensor
4Fuel delivery hose
5Fuel tank
6Fuel pump
7Fuel return hose
8Intake air presure sen-
sor
9Throttle position sen-
sor
10Fuel injector
11Catalytic converter
12Crankshaft position
sensor
FUEL INJECTION SYSTEM
FUEL INJECTION SYSTEM
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9-1
STARTING FAILURES
TRBL
SHTG
NOTE:
FUEL SYSTEM
Fuel tank
Empty fuel tank

Clogged fuel filter

Clogged fuel strainer

Clogged fuel tank drain hose

Deteriorated or contaminated fuel
Fuel pump
Faulty fuel pump

Faulty fuel pump relay
Throttle body (-ies)

Deteriorated or contaminated fuel

Sucked-in air
Ignition coil(s)
Cracked or broken ignition coil body

Broken or shorted primary or secondary
coils
Ignition system
Faulty ECU

Faulty crankshaft position sensor
EAS00844
TROUBLESHOOTING
The following guide for troubleshooting does not cover all the possible \
causes of trouble. It should be
helpful, however, as a guide to basic troubleshooting. Refer to the relative procedure i\
n this manual for
checks, adjustments, and replacement of parts.
STARTING FAILURES
ENGINE
Cylinder(s) and cylinder head(s)

Loose spark plug

Loose cylinder head or cylinder

Damaged cylinder head gasket

Damaged cylinder gasket

Worn or damaged cylinder

Incorrect valve clearance

Improperly sealed valve

Incorrect valve-to-valve-seat contact

Incorrect valve timing

Faulty valve spring

Seized valve
Piston(s) and piston ring(s)
Improperly installed piston ring

Damaged, worn or fatigued piston ring

Seized piston ring

Seized or damaged piston
Air filter
Improperly installed air filter

Clogged air filter element
Crankcase and crankshaft
Improperly assembled crankcase

Seized crankshaft
ELECTRICAL SYSTEMS
Battery
Discharged battery

Faulty battery
Fuse(s)
Blown, damaged or incorrect fuse

Improperly installed fuse
Spark plug(s)

Incorrect spark plug gap

Incorrect spark plug heat range

Fouled spark plug

Worn or damaged electrode

Worn or damaged insulator
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9-2
9
Starting system
Faulty starter motor

Faulty starter relay

Faulty starting circuit cut-off relay

Faulty starter clutch
STARTING FAILURES / INCORRECT ENGINE IDLING SPEED /
POOR MEDIUM-AND-HIGH-SPEED PERFORMANCETRBL
SHTG
ELECTRICAL SYSTEMS
Battery

Discharged battery

Faulty battery
Spark plug(s)
Incorrect spark plug gap

Incorrect spark plug heat range

Fouled spark plug

Worn or damaged electrode

Worn or damaged insulator
Ignition coil(s)

Broken or shorted primary or secondary
coils

Cracked or broken ignition coil
Ignition system
Faulty ECU

Faulty crankshaft position sensor
Switches and wiring

Faulty main switch

Faulty engine stop switch

Broken or shorted wiring

Faulty neutral switch

Faulty start switch

Faulty sidestand switch

Faulty clutch switch

Improperly grounded circuit

Loose connections
EAS00846
INCORRECT ENGINE IDLING SPEED
ENGINE
Cylinder(s) and cylinder head(s)

Incorrect valve clearance

Damaged valve train components
Air filter
Clogged air filter element
FUEL SYSTEM
Throttle body (-ies)
Damaged or loose throttle body joint

Improperly synchronized throttle bodies

Improperly adjusted engine idling speed (idle
adjusting screw)

Improper throttle cable free play

Flooded throttle body

Faulty air induction system
EAS00848
POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE
Refer to “STARTING FAILURES”.
ENGINE
Air filter

Clogged air filter element
FUEL SYSTEM
Fuel pump
Faulty fuel pump
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9-4
OVERHEATING / OVERCOOLING /
POOR BRAKING PERFORMANCETRBL
SHTG
FUEL SYSTEM
Throttle body (-ies)

Damaged or loose throttle body joint
Air filter

Clogged air filter element
CHASSIS
Brake(s)

Dragging brake
ELECTRICAL SYSTEMS
Spark plug(s)

Incorrect spark plug gap

Incorrect spark plug heat range
Ignition system

Faulty E.C.U.

Loose union bolt

Damaged brake hose

Oil or grease on the brake disc

Oil or grease on the brake pad

Incorrect brake fluid level
EAS00855
OVERHEATING
ENGINE
Clogged coolant passages

Cylinder head(s) and piston(s)

Heavy carbon buildup
Engine oil

Incorrect oil level

Incorrect oil viscosity

Inferior oil quality
COOLING SYSTEM
Coolant

Low coolant level
Radiator

Damaged or leaking radiator

Faulty radiator cap

Bent or damaged radiator fin
Water pump

Damaged or faulty water pump

Thermostat

Thermostat stays closed

Oil cooler

Clogged or damaged oil cooler

Hose(s) and pipe(s)

Damaged hose

Improperly connected hose

Damaged pipe

Improperly connected pipe
EAS00856
OVERCOOLING
COOLING SYSTEM
Thermostat

Thermostat stays open
EAS00857
POOR BRAKING PERFORMANCE

Worn brake pad

Worn brake disc

Air in hydraulic brake system

Leaking brake fluid

Faulty brake caliper kit

Faulty brake caliper seal
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