YAMAHA YZF-R1S 2004 Owner's Manual

1-5
FEATURES
GEN
INFO
NOTE:
NOTE: To set the shift timing indicator light activation function
The shift timing indicator light activation function can be set between 7000 r/min and 15000 r/m. From
7000 r/min to 12000 r/min, the indicator light can be set in increments of 500 r/min. From 12000 r/min to
15000 r/min, the indicator light can be set in increments of 200 r/min.
1. Push the “RESET” button to select the desired engine speed for activating the indicator light.
2. Push the “SELECT” button to confirm the selected engine speed. The control mode changes to the
shift timing indicator light deactivation function.
To set the shift timing indicator light deactivation function

The shift timing indicator light activation function can be set between 7000 r/min and 15000 r/min.
From 7000 r/min to 12000 r/min, the indicator light can be set in increments of 500 r/min. From 12000
r/min to 15000 r/min, the indicator light can be set in increments of 200 r/min.

Be sure to set the deactivation function to a higher engine speed than for the activation function,
otherwise the shift timing indicator light will remain deactivated.
1. Push the “RESET” button to select the desired engine speed for deactivating the indicator light.
2. Push the “SELECT” button to confirm the selected engine speed. The control mode changes to the
shift timing indicator light brightness function.
To adjust the shift timing indicator light brightness
1. Push the “RESET” button to select the desired indicator light brightness level.
2. Push the “SELECT” button to confirm the selected indicator light brightness level. The right display
will return to the odometer or tripmeter mode
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1-6
springlip
oil
grease lip
IMPORTANT INFORMATION
GEN
INFO
EAS00020
IMPORTANT INFORMATION
PREPARATION FOR REMOVAL AND
DISASSEMBLY
1. Before removal and disassembly, eliminate
all dirt, mud, dust and foreign material.
2. Use only the proper tools and cleaning
equipment.
Refer to the “SPECIAL TOOLS”.
3. When disassembling, always keep mated
parts together. This includes gears, cylin-
ders, pistons and other parts that have been
“mated” through normal wear. Mated parts
must always be reused or replaced as an as-
sembly.
4. During disassembly, clean all of the parts
and place them in trays in the order of disas-
sembly. This will speed up assembly and al-
low for the correct installation of all parts.
5. Keep all parts away from any source of fire.
EAS00021
REPLACEMENT PARTS
Use only genuine Yamaha parts for all replace-
ments. Use oil and grease recommended by
Yamaha for all lubrication jobs. Other brands
may be similar in function and appearance, but
inferior in quality.
EAS00022
GASKETS, OIL SEALS AND O-RINGS
1. When overhauling the engine, replace all
gaskets, seals and O-rings. All gasket sur-
faces, oil seal lips and O-rings must be
cleaned.
2. During reassembly, properly oil all mating
parts and bearings and lubricate the oil seal
lips with grease.
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1-7
IMPORTANT INFORMATION
GEN
INFO
CAUTION:
EAS00023
LOCK WASHERS / PLATES AND COTTER
PINS
After removal, replace all lock washers / plates
1 and cotter pins. After the bolt or nut has been
tightened to specification, bend the lock tabs
along a flat of the bolt or nut.
EAS00024
BEARINGS AND OIL SEALS
Install bearings and oil seals so that the
manufacturer’s marks or numbers are visible.
When installing oil seals, lubricate the oil seal
lips with a light coat of lithium-soap-based
grease. Oil bearings liberally when installing, if
appropriate.
1Oil seal
Do not spin the bearing with compressed air
because this will damage the bearing sur-
faces.
1Bearing
EAS00025
CIRCLIPS
Before reassembly, check all circlips carefully
and replace damaged or distorted circlips. Al-
ways replace piston pin clips after one use.
When installing a circlip
1, make sure the
sharp-edged corner
2 is positioned opposite
the thrust
3 that the circlip receives.
4Shaft
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1-8
CHECKING THE CONNECTIONS
GEN
INFO
NOTE:
NOTE:
NOTE:
EAS00026
CHECKING THE CONNECTIONS
Check the leads, couplers, and connectors for
stains, rust, moisture, etc.
1. Disconnect:

lead

coupler

connector
2. Check:

lead

coupler

connector
Moisture
Dry with an air blower.
Rust / stains
Connect and disconnect sev-
eral times.
3. Check:

all connections
Loose connection
Connect properly.
If the pin
1 on the terminal is flattened, bend it
up.
4. Connect:

lead

coupler

connector
Make sure all connections are tight.
5. Check:

continuity
(with the pocket tester)
Pocket tester
90890-03112, YU-3112

If there is no continuity, clean the terminals.

When checking the wire harness, perform
steps (1) to (3).

As a quick remedy, use a contact revitalizer
available at most part stores.
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1-9
SPECIAL TOOLS
GEN
INFO
NOTE:
EAS00027
SPECIAL TOOLS
The following special tools are necessary for complete and accurate tune-up and assembly. Use only
the appropriate special tools as this will help prevent damage caused by the use of inappropriate tools
or improvised techniques. Special tools, part numbers or both may differ depending on the country.
When placing an order, refer to the list provided below to avoid any mistakes.

For U.S.A. and Canada, use part number starting with “YM-”, “YU-”, or “ACC-”.

For others, use part number starting with “90890-”.
Tool No.
Tool name / FunctionIllustration
90890-01304
YU-01304
Piston pin puller
This tool is used to remove the piston pins.
Radiator cap tester
90890-01325
YU-24460-01
Adapter
90890-01352
YU-33984Radiator cap tester
Radiator cap tester adapter
These tools are used to check the cooling
system.
90890-01403
YU-33975
Steering nut wrench
This tool is used to loosen or tighten the
steering stem ring nuts.
90890-01423
YM-01423
Damper rod holder
This tool is used to hold the damper rod as-
sembly when loosening or tightening the
damper rod assembly bolt.
90890-01426
YU-38411
Oil filter wrench
This tool is needed to loosen or tighten the
oil filter cartridge.
90890-01434
YM-01434
Rod holder
This tool is used to support the damper ad-
justing rod.
Rod puller
90890-01437
YM-01437
Rod puller
attachment
90890-01436
YM-01436Rod puller
Rod puller attachment
These tools are used to pull up the front
fork damper rod.
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1-10
SPECIAL TOOLS
GEN
INFO
Tool No.Tool name / FunctionIllustration
90890-01441
YM-01441
Fork spring compressor
This tool is used to disassemble or
assemble the front fork legs.
90890-01442
YM-01442
Fork seal driver
This tool is used to install the front fork’s oil
seal and dust seal.
90890-03094
YU-08030
Vacuum gauge
This guide is used to synchronize the car-
buretors.
Compression
gauge
90890-03081
YU-33223
Adapter
90890-04136Compression gauge
Compression gauge adapter
These tools are used to measure engine
compression.
Valve spring compressor
90890-04019
YM-04019
Attachment
90890-04108
YM-01253
90890-04114
YM-4114Valve spring compressor
Valve spring compressor attachment
These tools are used to remove or install
the valve assemblies.
Middle driven shaft
bearing driver
90890-04058
YM-4058
Mechanical seal
installer
90890-04078
YM-33221Middle driven shaft bearing driver
Mechanical seal installer
These tools are used to install the water
pump seal.
90890-04086
YM-91042
Clutch holding tool
This tool is used to hold the clutch boss
when removing or installing the clutch boss
nut.
90890-04111
90890-04116
YM-4116
Valve guide remover
This tool is used to remove or install the
valve guides.
90890-04112
90890-04117
YM-4117
Valve guide installer
This tool is used to install the valve guides.
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1-11
SPECIAL TOOLS
GEN
INFO
Tool No.Tool name / FunctionIllustration
90890-04113
YM-04113
90890-04118
YM-4118Valve guide reamer
This tool is used to rebore the new valve
guides.
90890-06754
YM-34487
Ignition checker
This tool is used to check the ignition sys-
tem components.
90890-85505
ACC-1109-0501
Yamaha bond No. 1215
This bond is used to seal two mating sur-
faces (e.g., crankcase mating surfaces).
90890-03174
Digital circuit tester
This tool is used to check the electrical sys-
tem.
Pivot shaft wrench
90890-01471
YM-01471
Pivot shaft wrench
adapter
90890-01476Pivot shaft wrench
Pivot shaft wrench adapter
This tool is need to loosen or tighten the
spacer bolt.
90890-03132
YU-3112
Pocket tester
This instrument is needed for checking the
engine oil temperature.
Oil pressure
gauge
90890-03153
YU-03153
Adapter
90890-03139Oil pressure gauge
Adapter
These tools are used to measure engine oil
pressure.
90890-06756
Vacuum/pressure pump gauge set
This tool used to measure the vacuum pres-
sure.
90793-80009
Engine tachometer
This tool is needed for observing engine
rpm.
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1-12
SPECIAL TOOLS
GEN
INFO
Tool No.Tool name / FunctionIllustration
90890-04101
Valve lapper
This tool is needed to remove and install
the valve lifter.
90890-03176
YM-03176
Fuel pressure adapter
This tool is needed to measure fuel pres-
sure.
90890-03153
YU-03153
Pressure gauge
This tool is used to measure fuel pressure.
90890-04143
YM-04143
Camshaft wrench
This tool is used to hold and rotate the cam-
shaft sprocket.
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2-1
GENERAL SPECIFICATIONSSPEC
SPECIFICATIONS
GENERAL SPECIFICATIONS
ItemStandardLimit
Model code5VY4 (USA), 5VY5 (CAL)



Dimensions
Overall length
Overall width
Overall height
Seat height
Wheelbase
Minimum ground clearance
Minimum turning radius
2,065 mm (8.13 in)
720 mm (28.3 in)
1,105 mm (43.5 in)
835 mm (32.9 in)
1,395 mm (54.9 in)
135 mm (5.31 in)
3,400 mm (133.9 in)



























Weight
Wet (with oil and a full fuel tank)
Maximum load (except motorcycle)
193 kg (425 lb) (USA)
194 kg (428 lb) (CAL)
202 kg (445 lb) (USA)
201 kg (443 lb) (CAL)







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2-2
ENGINE SPECIFICATIONSSPEC
2
ENGINE SPECIFICATIONS
ItemStandardLimit
Engine
Engine type
Displacement
Cylinder arrangement
Bore
stroke
Compression ratio
Engine idling speed
Vacuum pressure at engine idling
speed
Standard compression pressure
(at sea level)
Liquid-cooled, 4-stroke, DOHC
998 cm3 (60.90 cu.in)
Forward-inclined parallel 4-cylinder
77.0
53.6 mm (3.03
2.11 in)
12.4 : 1
1,150  1,250 r / min
22 kPa (165 mmHg, 6.5 inHg)
1,480 kPa (14.80 kg / cm
2,14.80 bar,
210.5 psi) at 350 r / min
































Fuel
Recommended fuel
Fuel tank capacity
Total (including reserve)
Reserve only
Premium unleaded gasoline only
18 L (3.96 Imp gal, 4.76 US gal)
3.4 L (0.75 Imp gal, 0.90 US gal)











Engine oil
Lubrication system
Recommended oil
Quantity
Total amount
Without oil filter cartridge
replacement
With oil filter cartridge replacement
Oil pressure
Engine oil temperature
Relief valve opening pressure
Wet sump
At 5C (40F) or higher
Yamalube 4 (20W40) or SAE 20W40
type SE motor oil
At 15C (60F) or lower
Yamalube 4 (10W30) or SAE 10W30
type SE motor oil
3.8 L (3.35 Imp qt, 4.02 US qt)
2.9 L (2.55 Imp qt, 3.07 US qt)
3.1 L (2.73 Imp qt, 3.28 US qt)
230 kPa at 5,000 r / min
(2.3 kg / cm
2 at 5,000 r / min)
(2.3 bar at 5,000 r / min)
(32.7 psi at 5,000 r / min)
100C (212F)
600  680 kPa (6.0  6.8 kg / cm
2,
6.0  6.8 bar, 87.0  98.6 psi)
























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