ABS YAMAHA YZF-R1S 2004 User Guide

3-59
AB
CHECKING THE TIRES
CHK
ADJ
WARNING
WARNING
2. Check:

tire surfaces
Damage / wear
Replace the tire.
Minimum tire tread depth
1.6 mm (0.06 in)
1Tire tread depth
2Sidewall
3Wear indicator

Do not use a tubeless tire on a wheel de-
signed only for tube tires to avoid tire fail-
ure and personal injury from sudden defla-
tion.

When using a tube tire, be sure to install the
correct tube.

Always replace a new tube tire and a new
tube as a set.

To avoid pinching the tube, make sure the
wheel rim band and tube are centered in the
wheel groove.

Patching a punctured tube is not recom-
mended. If it is absolutely necessary to do
so, use great care and replace the tube as
soon as possible with a good quality re-
placement.
ATire
BWheel
Tube wheelTube tire only
T beless wheelTube or tubelessTubeless wheeltire
After extensive tests, the tires listed below
have been approved by Yamaha Motor Co.,
Ltd. for this model. The front and rear tires
should always be by the same manufacturer
and of the same design. No guarantee con-
cerning handling characteristics can be giv-
en if a tire combination other than one ap-
proved by Yamaha is used on this
motorcycle.
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4-17
FRONT AND REAR BRAKESCHAS
CAUTION:
WARNING
EAS00579
Disc brake components rarely require dis-
assembly.
Therefore, always follow these preventive
measures:

Never disassemble brake components un-
less absolutely necessary.

If any connection on the hydraulic brake
system is disconnected, the entire brake
system must be disassembled, drained,
cleaned, properly filled, and bled after reas-
sembly.

Never use solvents on internal brake com-
ponents.

Use only clean or new brake fluid for clean-
ing brake components.

Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean
up any spilt brake fluid immediately.

Avoid brake fluid coming into contact with
the eyes as it can cause serious injury.
FIRST AID FOR BRAKE FLUID ENTERING
THE EYES:

Flush with water for 15 minutes and get im-
mediate medical attention.
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4-65
Order Job / Part Q’ty Remarks
1
2
3
4
5
6
7
8
9
10Removing the rear shock absorber
assembly
EXUP servo motor
Self-locking nut / bolt
Self-locking nut / bolt
Self-locking nut / bolt
Self-locking nut
Rear shock absorber assembly
Oil seal / bearing / collar
Collar / self-locking nut / bolt
Connecting arm
Oil seal / bearing / collar
Relay arm1/1
1/1
1/1
1
1
6/3/3
1/1/1
2
2/1/1
1Remove the parts in the order listed.
Refer to “EXHAUST PIPE” in chapter 5.
For installation, reverse the removal
procedure.
92 Nm (9.2 m
kg, 67 ft
lb)44 Nm (4.4 m
kg, 32 ft
lb)
44 Nm (4.4 m
kg, 32 ft
lb)44 Nm (4.4 m
kg, 32 ft
lb)
REAR SHOCK ABSORBER ASSEMBLYCHAS
EAS00685
REAR SHOCK ABSORBER ASSEMBLY
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4-66
REAR SHOCK ABSORBER ASSEMBLYCHAS
WARNING
WARNING
EAS00687
HANDLING THE REAR SHOCK ABSORBER
AND GAS CYLINDER
This rear shock absorber and gas cylinder
contain highly compressed nitrogen gas.
Before handling the rear shock absorber or
gas cylinder, read and make sure you under-
stand the following information. The
manufacturer cannot be held responsible
for property damage or personal injury that
may result from improper handling of the
rear shock absorber and gas cylinder.

Do not tamper or attempt to open the rear
shock absorber or gas cylinder.

Do not subject the rear shock absorber or
gas cylinder to an open flame or any other
source of high heat. High heat can cause an
explosion due to excessive gas pressure.

Do not deform or damage the rear shock
absorber or gas cylinder in any way. If the
rear shock absorber, gas cylinder or both
are damaged, damping performance will
suffer.
EAS00689
DISPOSING OF A REAR SHOCK
ABSORBER AND GAS CYLINDER
Gas pressure must be released before dispos-
ing of a rear shock absorber and gas cylinder. To
release the gas pressure, drill a 2
3 mm (0.08

0.12 in) hole through the gas cylinder at a
point 15
20 mm (0.59
0.79 in) from its end
as shown.
Wear eye protection to prevent eye damage
from released gas or metal chips.
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4-67
REAR SHOCK ABSORBER ASSEMBLYCHAS
WARNING
NOTE:
NOTE:
NOTE:
EAS00690
REMOVING THE REAR SHOCK ABSORBER
ASSEMBLY
1. Stand the motorcycle on a level surface.
Becurely support the motorcycle so that
there is no danger of it falling over.
Place the motorcycle on a suitable stand so that
the rear wheel is elevated.
2. Remove:

bottom cowling
Refer to “COWLINGS” in chapter 3.

servo motor
Refer to “EXHAUST PIPE” in chapter 5.
3. Remove:

rear shock absorber assembly lower bolt
1

relay arm-to-swingarm bolt 2
While removing the rear shock absorber as-
sembly lower bolt, hold the swingarm so that it
does not drop down.
4. Remove:

rear shock absorber assembly upper bolt
1

rear shock absorber assembly
Raise the swingarm and then remove the rear
shock absorber assembly from between the
swingarm.
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4-68
REAR SHOCK ABSORBER ASSEMBLYCHAS
NOTE:
44 Nm (4.4 m
kg, 32 ft
lb)
44 Nm (4.4 m
kg, 32 ft
lb)
44 Nm (4.4 m
kg, 32 ft
lb)
EAS00695
CHECKING THE REAR SHOCK ABSORBER
ASSEMBLY
1. Check:

rear shock absorber rod
Bends / damage
Replace the rear shock
absorber assembly.

rear shock absorber
Gas leaks / oil leaks
Replace the rear
shock absorber assembly.

spring
Damage / wear
Replace the rear shock ab-
sorber assembly.

bushings
Damage / wear
Replace.

dust seals
Damage / wear
Replace.

bolts
Bends / damage / wear
Replace.
EAS00698
INSTALLING THE REAR SHOCK
ABSORBER ASSEMBLY
1. Lubricate:

spacers

bearings
Recommended lubricant
Lithium – soap-based grease
2. Install:

rear shock absorber assembly

When installing the rear shock absorber as-
sembly, lift up the swingarm.

Install the connecting arm front bolt from the
right.
3. Tighten:

rear shock absorber assembly upper nut

rear shock absorber assembly lower nut

relay arm-to swingarm nut
4. Install :

EXUP servo motor
Refer to “EXHAUST PIPE” in chapter 5.

bottom cowling
Refer to “COWLINGS” in chapter 3.
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4-69
SWINGARM AND DRIVE CHAINCHAS
Order Job / Part Q’ty Remarks
1
2
3
4
5
6
7Removing the swingarm and drive
chain
Rear wheel
Rear shock absorber
Drive sprocket
Muffler
Catalyst pipe assembly
Right footrest bracket
Adjusting bolt / locknut
Drive chain guard
Rear fender
Brake hose holder
Pivot shaft nut / washer
Pivot shaft1
2/2
1
1
1
1/1
1Remove the parts in the order listed.
Refer to “REAR WHEEL AND BRAKE
DISC”.
Refer to “REAR SHOCK ABSORBER
ASSEMBLY”.
Refer to “ENGINE REMOVAL” in chapter
5.
Refer to “EXHAUST PIPE” in chapter 5.
Refer to “EXHAUST PIPE” in chapter 5.
28 Nm (2.8 m
kg, 20 ft
lb)
7 Nm (0.7 m
kg, 5.1 ft
lb)
7 Nm (0.7 m
kg, 5.1 ft
lb)
105 Nm (10.5 m
kg, 76 ft
lb)
2 Nm (0.2 m
kg, 1.4 ft
lb)
16 Nm (1.6 m
kg, 12 ft
lb)
EAS00700
SWINGARM AND DRIVE CHAIN
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4-71
SWINGARM AND DRIVE CHAINCHAS
WARNING
NOTE:
NOTE:
EAS00703
REMOVING THE SWINGARM
1. Stand the motorcycle on a level surface.
Securely support the motorcycle so that
there is no danger of it falling over.
Place the motorcycle on a suitable stand so that
the rear wheel is elevated.
2. Remove:

relay arm-to-swingarm bolt
1

connecting arm bolt 2

rear shock absorber assembly lower bolt 3
When removing the rear shock absorber as-
sembly lower bolt, hold the swingarm so that it
does not drop down.
3. Measure:

swingarm side play

swingarm vertical movement
a. Measure the tightening torque of the pivot
shaft nut.
Pivot shaft nut
105 Nm (10.5 m
kg, 76 ft
lb)
b. Measure the swingarm side play
A by mov-
ing the swingarm from side to side.
c. If the swingarm side play is out of specifica-
tion, check the spacers, bearings, washers,
and dust covers.
Swingarm side play
(at the end of the swingarm)
1.0 mm (0.04 in)
d. Check the swingarm vertical movement
B
by moving the swingarm up and down.
If swingarm vertical movement is not smooth
or if there is binding, check the spacers,
bearings, washers, and dust covers.
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4-75
SWINGARM AND DRIVE CHAINCHAS
6. Check:

drive sprocket

rear wheel sprocket
More than 1 / 4 tooth
a wear
Replace the
drive chain sprockets as a set.
Bent teeth
Replace the drive chain sprock-
ets as a set.
bCorrect
1Drive chain roller
2Drive chain sprocket
EAS00711
INSTALLING THE SWINGARM
1. Lubricate:

bearings

spacers

dust covers

pivot shaft
Recommended lubricant
Lithium-soap-based grease
2. Install:

swingarm

pivot shaft
1

pivot shaft nut 2
3. Install:

rear shock absorber assembly

rear wheel
Refer to “INSTALLING THE REAR SHOCK
ABSORBER ASSEMBLY” and “INSTAL-
LING THE REAR WHEEL”.
4. Adjust:

drive chain slack
Refer to “ADJUSTING THE DRIVE CHAIN
SLACK” in chapter 3.
Drive chain slack
25
35 mm (0.98
1.38 in)
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9-5
FAULTY FRONT FORK LEGS / UNSTABLE HANDLING
TRBL
SHTG
MALFUNCTION

Bent or damaged inner tube

Bent or damaged outer tube

Damaged fork spring

Worn or damaged outer tube bushing

Bent or damaged damper rod

Incorrect oil viscosity

Incorrect oil level
Rear shock absorber assembly(-ies)

Faulty rear shock absorber spring

Leaking oil or gas
Tire(s)

Uneven tire pressures (front and rear)

Incorrect tire pressure

Uneven tire wear
Wheel(s)

Incorrect wheel balance

Deformed cast wheel

Damaged wheel bearing

Bent or loose wheel axle

Excessive wheel runout
Frame

Bent frame

Damaged steering head pipe

Improperly installed bearing race
EAS00861
FAULTY FRONT FORK LEGS
LEAKING OIL

Bent, damaged or rusty inner tube

Cracked or damaged outer tube

Improperly installed oil seal

Damaged oil seal lip

Incorrect oil level (high)

Loose damper rod assembly bolt

Damaged damper rod assembly bolt
copper washer

Cracked or damaged cap bolt O-ring
EAS00863
UNSTABLE HANDLING
Handlebars

Bent or improperly installed right handlebar

Bent or improperly installed left handlebar
Steering head components

Improperly installed upper bracket

Improperly installed under bracket
(improperly tightened ring nut)

Bent steering stem

Damaged ball bearing or bearing race
Front fork leg(s)

Uneven oil levels (both front fork legs)

Unevenly tensioned fork spring (both front
fork legs)

Broken fork spring

Bent or damaged inner tube

Bent or damaged outer tube
Swingarm

Worn bearing or bushing

Bent or damaged swingarm
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