remove seats YAMAHA YZF-R1S 2004 User Guide

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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3-39
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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3-63
Relationship between the open-circuit voltage
and the charging time at 20C
Open-circuit voltage (V)
These values vary with the temperature, the condition of
the battery plates, and the electrolyte level. 13.0
12.5
12.0
11.5
5 6.5 10
Charging time (hours)
Ambient
temperature
20C
Open-circuit voltage (V)
Charging condition of the battery (%)
CHECKING AND CHARGING THE BATTERY
CHK
ADJ
NOTE:
CAUTION:
NOTE:
Since MF batteries are sealed, it is not possible
to check the charge state of the battery by mea-
suring the specific gravity of the electrolyte.
Therefore, the charge of the battery has to be
checked by measuring the voltage at the battery
terminals.
1. Remove:

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

battery leads
(from the battery terminals)
First, disconnect the negative battery lead
1, and then the positive battery lead 2.
3. Remove:

battery
4. Check:

battery charge
a. Connect a pocket tester to the battery termi-
nals.
Pocket tester
90890-03112, YU-3112
Positive tester probe

positive battery terminal
Negative tester probe

negative battery terminal

The charge state of an MF battery can be
checked by measuring its open-circuit voltage
(i.e., the voltage when the positive battery ter-
minal is disconnected).

No charging is necessary when the open-cir-
cuit voltage equals or exceeds 12.8 V.
b. Check the charge of the battery, as shown in
the charts and the following example.
Example
c. Open-circuit voltage = 12.0 V
d. Charging time = 6.5 hours
e. Charge of the battery = 20
30%
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3-67
CHECKING AND CHARGING THE BATTERY /
CHECKING THE FUSESCHK
ADJ
CAUTION:
CAUTION:
NOTE: 6. Install:

battery
7. Connect:

battery leads
(to the battery terminals)
First, connect the positive battery lead
1,
and then the negative battery lead
2.
8. Check:

battery terminals
Dirt
Clean with a wire brush.
Loose connection
Connect properly.
9. Lubricate:

battery terminals
Recommended lubricant
Dielectric grease
10. Install:

rider seat
Refer to “SEATS”.
EAS00181
CHECKING THE FUSES
The following procedure applies to all of the
fuses.
To avoid a short circuit, always set the main
switch to “OFF” when checking or replacing
a fuse.
1. Remove:

front cowling inner panel (left)
Refer to “COWLINGS”.

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

fuse
a. Connect the pocket tester to the fuse and
check the continuity.
Set the pocket tester selector to “Ω  1”.
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5-2
5
Order Job / Part Q’ty Remarks
1
2
3
4
5
6
7
8
9
10Removing the exhaust pipe
Rider seat and passenger seat
Fuel tank
Side cowlings and bottom cowlings
EXUP pulley cover
EXUP cable
Exhaust pipe assembly
Exhaust pipe gasket
Exhaust valve pipe gasket
Exhaust valve pipe assembly
Catalyst pipe assembly
Gasket
Muffler
Gasket1
2
1
4
1
1
1
1
2
2Remove the parts in the order listed.
Refer to “SEATS” in chapter 3.
Refer to “FUEL TANK” in chapter 3.
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)
20 Nm (2.0 m
kg, 14 ft
lb)
20 Nm (2.0 m
kg, 14 ft
lb)
20 Nm (2.0 m
kg, 14 ft
lb)
23 Nm (2.3 m
kg, 17 ft
lb)
ENGINEENG
EXHAUST PIPE
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5-23
CYLINDER HEADENG
NOTE:
NOTE:
NOTE:
EAS00222
REMOVING THE CYLINDER HEAD
1. Remove:

intake camshaft

exhaust camshaft
Refer to “REMOVING THE CAMSHAFTS”.
2. Remove:

cylinder head nuts

cylinder head bolts

Loosen the nuts in the proper sequence as
shown.

Loosen each nut 1 / 2 of a turn at a time. After all
of the nuts are fully loosened, remove them.
EAS00227
CHECKING THE CYLINDER HEAD
1. Eliminate:

combustion chamber carbon deposits
(with a rounded scraper)
Do not use a sharp instrument to avoid damag-
ing or scratching:

spark plug bore threads

valve seats
2. Check:

cylinder head
Damage / scratches
Replace.
3. Measure:

cylinder head warpage
Out of specification
Resurface the cylin-
der head.
Maximum cylinder head warpage
0.10 mm (0.0039 in)
a. Place a straightedge
1 and a thickness
gauge
2 across the cylinder head.
b. Measure the warpage.
c. If the limit is exceeded, resurface the cylinder
head as follows.
d. Place a 400
600 grit wet sandpaper on the
surface plate and resurface the cylinder
head using a figure-eight sanding pattern.
To ensure an even surface, rotate the cylinder
head several times.
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5-27
VALVES AND VALVE SPRINGSENG
NOTE:
NOTE:
NOTE:
NOTE:
EAS00237
REMOVING THE VALVES
The following procedure applies to all of the
valves and related components.
Before removing the internal parts of the cylin-
der head (e.g., valves, valve springs, valve
seats), make sure the valves properly seal.
1. Remove:

valve lifter
1

valve pad 2
Make a note of the position of each valve lifter
and valve pad so that they can be reinstalled in
their original place.
2. Check:

valve sealing
Leakage at the valve seat
Check the valve
face, valve seat, and valve seat width.
Refer to “CHECKING THE VALVE SEATS”.
a. Pour a clean solvent
a into the intake and
exhaust ports.
b. Check that the valves properly seal.
There should be no leakage at the valve seat
1.
3. Remove:

valve cotters
1
Remove the valve cotters by compressing the
valve spring with the valve spring compressor
2 and the valve spring compressor attachment
3.
Valve spring compressor
90890-04019, YM-04019
Valve spring compressor
attachment
Intake valve
90890-04114, YM-4114
Exhaust valve
90890-04108, YM-4108
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5-35
Order Job / Part Q’ty Remarks
1
2
3
4
5
6
7
8
9Removing the stator coil assembly
Rider seat
Fuel tank
Left side cowling
Bottom cowlings
Engine oil
Stator coil assembly lead coupler
Plug
Generator rotor cover
Gasket
Dowel pin
Generator rotor assembly
Dowel pin
Bearing housing
Collar1
1
1
1
2
1
2
1
1Remove the parts in the order listed.
Refer to “SEATS” in chapter 3.
Refer to “FUEL TANK” in chapter 3.
Refer to “COWLINGS” in chapter 3.
Drain.
Refer to “CHANGING THE ENGINE OIL”
in chapter 3.
Disconnect.
10 Nm (1.0 m
kg, 7.2 ft
lb)
12 Nm (1.2 m
kg, 8.7 ft
lb)
12 Nm (1.2 m
kg, 8.7 ft
lb)
12 Nm (1.2 m
kg, 8.7 ft
lb)
10 Nm (1.0 m
kg, 7.2 ft
lb)
10 Nm (1.0 m
kg, 7.2 ft
lb)
14 Nm (1.4 m
kg, 10 ft
lb)
22 Nm (2.2 m
kg, 16 ft
lb)
22 Nm (2.2 m
kg, 16 ft
lb)
STARTER CLUTCH AND GENERATORENG
STARTER CLUTCH AND GENERATOR
STATOR COIL ASSEMBLY
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5-38
STARTER CLUTCH AND GENERATORENG
NOTE: REMOVING THE GENERATOR
1. Remove:

rider seat

fuel tank
Refer to “SEATS” and “FUEL TANK” in chapter
3.
2. Remove:

left side cowling

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

engine oil
Refer to “CHANGING THE ENGINE OIL” in
chapter 3.
4. Remove:

plug

generator rotor cover
1

While pushing generator rotor, remove the
generator rotor cover.

Loosen each bolt 1 / 4 of a turn a time, in stages
and in a crisscross pattern.

After all of the bolts are fully loosened, remove
them.
5. Remove:

generator rotor and starter clutch assembly
1.
6. Remove:

idler gear shaft bolt
1

idler shaft

idler gear
2
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5-43
Order Job / Part Q’ty Remarks
1
2
3
4
5
6Removing the crankshaft position
sensor
Rider seat
Fuel tank
Side cowlings
Bottom cowlings
Engine oil
Crankshaft position sensor lead coupler
Crankshaft position sensor
O-ring
Pickup rotor cover
Gasket
Cover1
1
1
1
1
1Remove the parts in the order listed.
Refer to “SEATS” in chapter 3.
Refer to “FUEL TANK” in chapter 3.
Refer to “COWLINGS” in chapter 3.
Drain.
Refer to “CHANGING THE ENGINE OIL”
in chapter 3.
Disconnect.
For installation, reverse the removal
procedure.
10 Nm (1.0 m
kg, 7.2 ft
lb)
12 Nm (1.2 m
kg, 8.7 ft
lb)
12 Nm (1.2 m
kg, 8.7 ft
lb)
12 Nm (1.2 m
kg, 8.7 ft
lb)
CRANKSHAFT POSITION SENSORENG
CRANKSHAFT POSITION SENSOR
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