YAMAHA YZF-R1S 2004 Manual Online

3-4
Order Job / Part Q’ty Remarks
1
2
3
4
5
6
7
8
9
10
11Removing the fuel tank
Rider sear
Fuel tank side cover
Fuel hose connector cover
Fuel hose
Fuel return hose
Fuel sender coupler
Fuel pump coupler
Fuel tank over flow hose
Fuel tank breather hose
Fuel tank
Fuel tank cover
Fuel pump2
1
1
1
1
1
1
1
1
1
1Remove the parts in the order listed.
Refer to “SEATS”.
Disconnect.
Disconnect.
Disconnect.
Disconnect.
Disconnect.
Disconnect.
Disconnect.
For installation, reverse the removal
procedure.
10 Nm (1.0 m
kg, 7.2 ft
lb)
10 Nm (1.0 m
kg, 7.2 ft
lb)
4 Nm (0.4 m
kg, 2.9 ft
lb)
4 Nm (0.4 m
kg, 2.9 ft
lb)
FUEL TANK
CHK
ADJ
EAS00040
FUEL TANK
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3-5
FUEL TANK
CHK
ADJ
CAUTION:
NOTE:
NOTE:
CAUTION:
REMOVING THE FUEL TANK
1. Extract the fuel in the fuel tank through the
fuel tank cap with a pump.
2. Remove:

fuel hose connector cover

fuel return hose

fuel hose

fuel sender coupler

fuel pump coupler

fuel tank breather hose

fuel tank over flow hose
Although the fuel has been removed from
the fuel tank, be careful when removing the
fuel hoses, since there may be fuel remain-
ing in it.
Before removing the hoses, place a few rags in
the area under where it will be removed.
3. Remove:

fuel tank
Do not set the fuel tank down so that the installa-
tion surface of the fuel pump is directly under the
tank. Be sure to lean the fuel tank in an upright
position.
REMOVING THE FUEL PUMP
1. Remove:

fuel pump

Do not drop the fuel pump or give it a
strong shock.

Do not touch the base section of the fuel
sender.
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3-6
FUEL TANK
CHK
ADJ
4 Nm (0.4 m
kg, 2.9 ft
lb)
NOTE:
CAUTION:
INSTALLING THE FUEL PUMP
1. Install:

fuel pump

Do not damage the installation surfaces of the
fuel tank when installing the fuel pump.

Always use a new fuel pump gasket.

Install the fuel pump as shown in the illustra-
tion.

Tighten the fuel pump bolts in stages in a criss-
cross pattern and to the specified torque.
INSTALLING THE FUEL TANK
1. Install:

fuel hose

fuel return hose

fuel hose connector cover
When installing the fuel hose, make sure
that it is securely connected, and that the
fuel hose holder is in the correct position,
otherwise the fuel hose will not be properly
installed.
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3-7
Order Job / Part Q’ty Remarks
1
2
3
4
5
6
7
8
9
10
11
12
13Removing the front cowling and
side cowlings
Rider seat
Side cowling
Front turn signal light lead coupler
Side cowling inner panel
Bottom cowling
Bottom cowing front cover
Frame side cover
Frame side panel
Headlight panel
Front cowling
Rear view mirror
Windshield
Air intake duct
Air intake duck mount2
2
2
2
1
2
2
2
1
2
1
2
2Remove the parts in the order listed.
Refer to “SEATS”.
Disconnect.
For installation, reverse the removal
procedure.
7 Nm (0.7 m
kg, 5.1 ft
lb)
7 Nm (0.7 m
kg, 5.1 ft
lb)
16 Nm (1.6 m
kg, 12 ft
lb)
COWLINGS
CHK
ADJ
COWLINGS
FRONT COWLING AND SIDE COWLINGS
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3-8
Order Job / Part Q’ty Remarks
1
2
3
4
5
6Removing the rear cowling
Rider seat and passenger seat
Muffler
Rear cowling (upper)
Tail / brake light lead coupler
Rear turn signal light lead coupler
Tail / brake light
License plate bracket assembly
Rear cowling (lower)1
1
4
1
1
1Remove the parts in the order listed.
Refer to “SEATS”.
Refer to “EXHAUST PIPE” in chapter 5.
Disconnect.
Disconnect.
For installation, reverse the removal
procedure.
4 Nm (0.4 m
kg, 2.9 ft
lb)10 Nm (1.0 m
kg, 7.2 ft
lb)
COWLINGS
CHK
ADJ
REAR COWLING
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3-9
COWLINGS
CHK
ADJ
NOTE:
NOTE: REMOVAL
1. Remove:

rear cowling

side cowlings
To remove the quick fastener, push its center
with a screwdriver, then pull the fastener out.
INSTALLATION
1. Install:

side cowlings

rear cowling
To install the quick fastener, push its pin so that it
protrudes from the fastener head, then insert
the fastener into the cowling and push the pin
a
in with a screwdriver. Make sure that the pin is
flush with the fastener’s head.
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3-10
Order Job / Part Q’ty Remarks
1
2
3
4
5
6
7
8
9
10Removing the air filter case
Rider sear
Fuel tank
Plug
Air temperature sensor lead coupler
Spacer
Air temperature sensor
Air filter case cover
Air filter
Funnel
Air filter case
Air induction system hose
Crankcase breather hose1
1
1
1
1
1
2
1
1
1Remove the parts in the order listed.
Refer to “SEATS”.
Refer to “FUEL TANK”.
Disconnect.
Disconnect.
Disconnect.
For installation, reverse the removal
procedure.
2 Nm (0.2 m
kg, 1.4 ft
lb)
3.4 Nm (0.34 m
kg, 2.5 ft
lb)
AIR FILTER CASE
CHK
ADJ
AIR FILTER CASE
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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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3-12
ADJUSTING THE VALVE CLEARANCE
CHK
ADJ
NOTE:
NOTE:
4. Measure:

valve clearance
Out of specification
Adjust.
Valve clearance (cold)
Intake valve
0.11  0.20 mm
(0.0043  0.0079 in)
Exhaust valve
0.21  0.25 mm
(0.0083  0.0098 in)
a. Turn the crankshaft counterclockwise.
b. When piston #1 is at TDC on the compres-
sion stroke, align the TDC mark
a on the
pickup rotor with the crankcase mating sur-
face
b.
TDC on the compression stroke can be found
when the camshaft lobes are turned away from
each other.
c. Measure the valve clearance with a thick-
ness gauge
1.

If the valve clearance is incorrect, record the
measured reading.

Measure the valve clearance in the following
sequence.
Valve clearance measuring sequence
Cylinder #1
#2
#4
#3
AFront
d. To measure the valve clearances of the other
cylinders, starting with cylinder #1 at TDC,
turn the crankshaft counterclockwise as spe-
cified in the following table.
BDegrees that the crankshaft is turned counter-
clockwise
CCylinder
DCombustion cycle
Cylinder #2180
Cylinder #4360
Cylinder #3540
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3-13
ADJUSTING THE VALVE CLEARANCE
CHK
ADJ
NOTE:
NOTE:
NOTE: 5. Remove:

camshafts

Refer to “DISASSEMBLING THE ENGINE –
CAMSHAFT AND CYLINDER HEAD” in chap-
ter 5.

When removing the timing chain and cam-
shafts, fasten the timing chain with a wire to re-
trieve it if it falls into the crankcase.
6. Adjust:

valve clearance
a. Remove the valve lifter
1 and the valve pad
2 with a valve lapper 3.
Valve lapper
90890-04101

Cover the timing chain opening with a rag to
prevent the valve pad from falling into the
crankcase.

Make a note of the position of each valve lifter
2 and valve pad 1 so that they can be
installed in the correct place.
b. Select the proper valve pad from the follow-
ing table.
Valve pad
thickness range
Available valve
pads
Nos.
120 
2401.20
(0.0472) 
2.40 mm
(0.0945 in)25 thicknesses in
0.05 mm (0.002 in)
increments

The thickness a of each valve pad is marked
in hundredths of millimeters on the side that
touches the valve lifter.

Since valve pads of various sizes are originally
installed, the valve pad number must be
rounded in order to reach the closest equiva-
lent to the original.
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