engine oil YAMAHA YZF-R1S 2004 User Guide

2-10
ENGINE SPECIFICATIONSSPEC
ItemStandardLimit
Transmission
Transmission type
Primary reduction system
Primary reduction ratio
Secondary reduction system
Secondary reduction ratio
Operation
Gear ratios
1st gear
2nd gear
3rd gear
4nd gear
5th gear
6th gear
Max. main axle runout
Max. drive axle runout
Constant mesh, 6-speed
Spur gear
65 / 43 (1.512)
Chain drive
45 / 17 (2.647)
Left-foot operation
38 / 15 (2.533)
33 / 16 (2.063)
37 / 21 (1.762)
35 / 23 (1.522)
30 / 22 (1.364)
33 / 26 (1.269)























































0.08 mm
(0.0032 in)
0.08 mm
(0.0032 in)
Shifting mechanism
Shift mechanism type
Max. shift fork guide bar bending
Shift drum / Guide bar







0.10 mm
(0.0039 in)
Air filter typeOil coated paper element



Fuel pump
Pump type
Model (manufacturer)
Output pressure
Electrical
5PW (DENSO)
294 kPa (2.94 kg / cm
2, 2.94 bar, 42.6 psi)












Throttle position sensor
Resistance
Output voltage (at idle)
4.9  5.1 kΩ at 20C (68F)
0.63  0.73 V



Throttle bodies
Model (manufacturer)
quantity
Intake vacuum pressure
Throttle cable free play (at the flange
45EIDW (MIKUNI)
2
22 kPa (165 mmHg, 6.4966 inHg)
3  5 mm (0.12  0.20 in)











of the throttle grip)
ID mark
Throttle valve size
5VY1 00 (USA)
5VY5 10 (CAL)
#100







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2-16
ELECTRICAL SPECIFICATIONSSPEC
ItemStandardLimit
Indicator light
(voltage / wattage
quantity)
Neutral indicator light
High beam indicator light
Oil level warning light
Turn signal indicator light
Fuel level warning light
Coolant temparture indicator light
Engine trouble warning light
Shift timing indicator light
LED
1
LED
1
LED
1
LED
2
LED
1
LED
1
LED
1
LED
1































Electric starting system
System type
Starter motor
Model (manufacturer)
Power output
Brushes
Overall length
Spring force
Armature coil resistance
Commutator diameter
Mica undercut
Constant mesh
5VY (YAMAHA)
0.9 kW
10.8 mm (0.43 in)
5.28  7.92 N (538  808 g,
18.99  28.48 oz)
0.0090  0.0110 Ω at 20C (68F)
24.5 mm (0.96 in)
1.5 mm (0.06 in)











3.6 mm
(0.14 in)








23.5 mm
(0.93 in)




Starter relay
Model (manufacturer)
Amperage
Coil resistance
2768079-A (JIDECO)
180 A
4.18  4.62 Ω at 20C (68F)











Horn
Horn type
Model (manufacturer)
quantity
Max. amperage
Performance
Coil resistance
Plane
YF-12 (NIKKO)
1
3 A
105  113 db / 2 m
1.15  1.25 Ω at 20C (68F)



















Turn signal relay
Relay type
Model (manufacturer)
Self-cancelling device built-in
Turn signal blinking frequency
Wattage
Full transistor
FE218BH (DENSO)
No
75  95 cycles / min.
21 W
2 + 3.4 W



















Oil level switch
Model (manufacturer)
5VY (SOMIC ISHIKAWA)



EXUP servo motor
Model (manufacturer)
5VY (YAMAHA)



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2-19
TIGHTENING TORQUESSPEC
Use a lock
washer
TIGHTENING TORQUES
ENGINE TIGHTENING TORQUES
ItemFastenerThreadQ’tyTightening torqueRemarksItemFastenersizeQtyNmm
kgft
lbRemarks
Spark plugs—M104131.39.4
Cylinder headNutM1010See NOTE 1
BoltM62121.28.7
Camshaft capsBoltM628101.07.2
Cylinder head coverBoltM66121.28.7
Cylinder head (exhaust pipe)Stud boltM88151.511
Air indication system capBoltM64101.07.2
Camshaft sprocketsBoltM74242.417
Cylinder head and throttle bodyClampM5430.32.2
Connecting rod capsBoltM8820+1502.0+15014+150
Generator rotorBoltM101606.043
Timing chain tensionerBoltM62101.07.2
Water pump outlet pipeBoltM61101.07.2
Water pump inlet pipeBoltM61101.07.2
(water pump side)
Water pump inlet pipe (front side)BoltM61101.07.2
Oil / water pump assembly
sprocketBoltM61151.511
Water pumpBoltM62121.28.7
Thermostat coverNutM62101.07.2
Thermostat inlet pipeBoltM61101.07.2
Oil coolerBoltM201636.346
Engine oil drain boltBoltM141434.331
Oil pipeBoltM62101.07.2
Oil strainerBoltM63101.07.2
Oil delivery pipeBoltM63101.07.2
Oil filter union boltBoltM201707.051
Oil filter—M201171.712
Oil panBoltM614121.28.7
Oil panBoltM61121.28.7
Air filter case coverScrewM5101.70.171.2
Throttle body and throttle body
jointClampM5430.32.2
Throttle body and funnelBoltM564.20.423.0
Throttle cableNutM614.50.453.3
Throttle cable adjusterBoltM614.50.453.3
Stator coilScrewM63141.410
Generator rotor cover and
bearing housingScrewM63101.07.2
Pull lever coverBoltM62101.07.2
Thermostat assembly stayBoltM62101.07.2
Starter clutch idler gearBoltM61101.07.2
Clutch bossNutM201959.569Stake
Clutch springBoltM66101.07.2
Drive sprocketNutM221858.561
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2-25
LUBRICATION POINTS AND LUBRICANT TYPESSPEC
EAS00031
LUBRICATION POINTS AND LUBRICANT TYPES
ENGINE
Lubrication point
Lubricant
Oil seal lips
O-rings
Bearings
Crankshaft pins
Piston surfaces
Piston pins
Crankshaft journals
Camshaft lobes
Camshaft journals
Valve stems (intake and exhaust)
Valve stem ends (intake and exhaust)
Water pump impeller shaft
Oil pump rotors (inner and outer)
Oil pump housing
Oil strainer
Clutch (pull rod)
Oil / water pump drive sprocket and washer
Clutch (thrust plate)
Starter clutch idle gear inner surface
Starter clutch assembly
Primary driven gear
Transmission gears (wheel and pinion)
Main axle and drive axle
Shift drum
Shift forks and shift fork guide bars
Shift shaft
Shift shaft boss
Cylinder head cover mating surfaceYamaha bond
No.1215
Crankcase mating surfaceYamaha bond
No.1215
Clutch cover (crankcase mating surface)Yamaha bond
No.1215
Generator rotor cover (crankcase mating surface)Yamaha bond
No.1215
Pickup rotor coverYamaha bond
No.1215
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2-26
LUBRICATION POINTS AND LUBRICANT TYPESSPEC
EAS00032
CHASSIS
Lubrication point
Lubricant
Steering bearings and bearing races (upper and lower)
Throttle grip inner surface
Brake lever pivoting point and metal-to-metal moving parts
Clutch lever pivoting point and metal-to-metal moving parts
Engine mount bolts (rear upper and lower)
Relay arm, connecting rod and rear shock absorber collar
Pivot shaft
Swingarm pivot bearing
Swingarm head pipe end, oil seal and bush
Oil seal (relay arm, connecting arm and rear shock absorber)
Seat lock assembly moving parts
Sidestand pivoting pint and metal-to-metal moving parts
Link and sidestand switch contact point
Sidestand hook and spring
Shift shaft joint
Front wheel oil seal (right and left)
Front axle shaft
Rear wheel oil seal
Rear wheel drive hub oil seal
Rear wheel drive hub mating surface
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2-29
ENGINE OIL LUBRICATION CHARTSPEC
ENGINE OIL LUBRICATION CHART
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2-39
E Clamp the clamp upper end
along the line of lower end of the
hose clamp assembly. Point the
tip of the clamp (surplus section)
to the front side of the vehicle.
Clutch cable is what the clamp
fastens.
F The clutch cable doesn’t project
outside the water hose and the
cylinder head in the box part in
the figure.
G To the engine
H Clamp behind the bracket 3.17Throttle body lead
A Clamp it after passing between
the frame and radiator stay.
Point the tip of the clamp (exces-
sive part) to the front side of the
vehicle. Fasten the right handle-
bar switch lead with a clamp.
B To the wire harness
C The clutch cable positioning
guide should be above the upper
end of the clamp. Fasten the
clutch cable with a clamp. (Refer
to )
D Position relation between the
clamp and guide.
M
CABLE ROUTINGSPEC
1Wire harness
2Crankshaft position sensor lead
3Heat protector
4Right handlebar switch lead
5Positioning guide
6Rear brake light switch lead
7Coolant reservoir tank
8Speed sensor lead
9Clutch cable
10Radiator
11Oil cooler outlet hose
12Coolant reservoir tank drain
hose
13Breather pipe
14Fuel tank drain hose
15A.C. magneto lead
16Wire harness
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3-2
NOTE:
GENERAL MAINTENANCE AND LUBRICATION CHART
CHK
ADJ
NOTE:
INITIALODOMETER READINGS
No.ITEMROUTINE600 mi
(1000 km)
or
1 month4000 mi
(7000 km)
or
6 months8000 mi
(13000 km)
or
12 months12000 mi
(19000 km)
or
18 months16000 mi
(25000 km)
or
24 months20000 mi
(31000 km)
or
30 months
9*Swingarm pivot
bearings
(See page 4-71)
Check bearing assemblies for looseness.
Moderately repack with lithium-soap-based
grease.
Repack.
10Drive chain
(See page 3-49, 50)
Check chain slack/alignment and condition.
Adjust and lubricate chain with a special O-
ring chain lubricant thoroughly.Every 600 mi (800 km) and after washing the motorcycle or riding in the rain
11*Steering bearings
(See page 3-51)
Check bearing assembly for looseness.
Moderately repack with lithium-soap-based
grease every 16000 mi (25000 km) or 24
months.



Repack.

12*Steering damper
(See page 4-60)
Check operation and for oil leakage.





13*Chassis fasteners
(See page 2-23)
Check all chassis fitting and fasteners.
Correct if necessary.





14Brake and clutch
lever pivot shafts
(See page 3-61)
Apply lithium-soap-based grease (all-purpose
grease) lightly.





15Sidestand pivot(See page 3-61)

Check operation.

Apply lithium-soap-based grease (all-pur-
pose grease) lightly.





16*Sidestand switch
(See page 3-61, 8-4)
Check operation and replace if necessary.






17*Front fork
(See page 3-53)
Check operation and for oil leakage.
Replace if necessary.





18*Shock absorber
assembly
(See page 3-56, 4-67)
Check operation and for oil leakage.
Replace if necessary.





19*Rear suspension
link pivots
(See page 4-71)
Check operation.
Correct if necessary.


20Engine oil
(See page 3-26, 28)
Change (warm engine before draining.)






21*Engine oil filter cartridge
(See page 3-28)
Replace.



22*Cooling system

Check hoses for cracks or damage.
Replace if necessary.





22*Cooling system(See page 3-37, 38, 39)
Change with ethylene glycol antifreeze cool-
ant every 24 months.Change.
23*EXUP system
(See page 3-36)
Check operation, cable free play and pulley
position.
Every 12000 mi (19000 km)
24*Control cables
(See page 3-61)
Apply Yamaha chain and cable lube or en-
gine oil SAE 10W-30 thoroughly.






25*Throttle grip housing
and cable
(See page 3-22)
Check operation and free play.
Adjust the throttle cable free play if necessary.
Lubricate the throttle grip housing and cable.





* Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service.
From 24000 mi (37000 km) or 36 months, repeat the maintenance intervals starting from 8000 mi
(13000 km) or 12 months.
Air filter

This model’s air filter is equipped with a disposable oil-coated paper element, which must not be
cleaned with compressed air to avoid damaging it.

The air filter element needs to be replaced more frequently when riding in unusually wet or dusty areas.
Hydraulic brake service

After disassembling the brake master cylinders and calipers, always change the fluid. Regularly
check the brake fluid levels and fill the reservoirs as required.

Every two years replace the internal components of the brake master cylinders and calipers, and
change the brake fluid.

Replace the brake hoses every four years and if cracked or damaged.
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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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3-24
CHECKING THE SPARK PLUGS /
MEASURING THE COMPRESSION PRESSURECHK
ADJ
13 Nm (1.3 m
kg, 9.4 ft
lb)
NOTE:
NOTE:
CAUTION:
8. Install:

spark plugs

ignition coils
Before installing the spark plug, clean the spark
plug and gasket surface.
9. Install:

radiator upper bolts

radiator lower bolt
Refer to “RADIATOR” in chapter 6.
10. Install:

side cowlings

bottom cowlings
Refer to “COWLINGS”.
EAS00065
MEASURING THE COMPRESSION
PRESSURE
The following procedure applies to all of the cyl-
inders.
Insufficient compression pressure will result in a
loss of performance.
1. Measure:

valve clearance
Out of specification
Adjust.
Refer to “ADJUSTING THE VALVE CLEAR-
ANCE”.
2. Start the engine, warm it up for several min-
utes, and then turn it off.
3. Remove:

ignition coils

spark plugs
Before removing the spark plugs, use com-
pressed air to blow away any dirt accumu-
lated in the spark plug wells to prevent it
from falling into the cylinders.
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