check oil YAMAHA YZF-R1S 2004 Workshop Manual

5-105
TRANSMISSIONENG
NOTE:
12 Nm (1.2 m
kg, 8.7 ft
lb)
10 Nm (1.0 m
kg, 7.2 ft
lb)
NOTE: 2. Measure:

drive axle runout
(with a centering device and dial gauge
1)
Out of specification
Replace the drive
axle.
Drive axle runout limit
0.08 mm (0.0032 in)
3. Check:

transmission gears
Blue discoloration / pitting / wear
Replace
the defective gear(s).

transmission gear dogs
Cracks / damage / rounded edges
Replace
the defective gear(s).
INSTALLING THE TRANSMISSION
1. Install:

bearing
1
Make the seal side of bearing face to the outside
and install it close to the right end face of the
crankcase.

oil pipe
2
2. Install:

main axle assembly
1

bearing housing 2
LOCTITE

shift fork “C”

shift drum assembly

shift fork guide bar

shift fork guide bar retainer
LOCTITE

The embossed marks on the shift forks should
face towards the right side of the engine and
be in the following sequence: “R”, “C”, “L”.

Carefully position the shift forks so that they
are installed correctly into the transmission
gears.

Install shift fork “C” into the groove in the 3rd
and 4th pinion gear on the main axle.
ProCarManuals.com

5-106
TRANSMISSIONENG
10 Nm (1.0 m
kg, 7.2 ft
lb)
NOTE:
NOTE: 3. Install:

shift fork “L”
1 and “R” 2

drive axle assembly 3

shift fork guide bar

shift fork guide bar retainer
4
LOCTITE

Install shift fork “L” into the groove in the 6th
wheel gear and shift fork “R” into the groove in
the 5th wheel gear on the drive axle.

Make sure that the drive axle bearing circlip
a
is inserted into the grooves in the upper crank-
case.
4. Check:

transmission
Rough movement
Repair.
Oil each gear, shaft, and bearing thoroughly.
ProCarManuals.com

6-7
OIL COOLERCOOL
63 Nm (6.3 m
kg, 46 ft
lb)
NOTE:
EAS00458
CHECKING THE OIL COOLER
1. Check:

oil cooler
Cracks / damage
Replace.
2. Check:

oil cooler inlet hose

oil cooler outlet hose
Cracks / damage / wear
Replace.
EAS00459
INSTALLING THE OIL COOLER
1. Clean:

mating surfaces of the oil cooler and the
crankcase
(with a cloth dampened with lacquer thinner)
2. Install:

O-ring
New

oil cooler
1

washer 2 New

bolt
3

Before installing the oil cooler, lubricate the oil
cooler bolt and O-ring with a thin coat of engine
oil.

Make sure that the O-ring is positioned proper-
ly.

Align the projection
a on the oil cooler with the
slot
b in the crankcase.
3. Fill:

cooling system
(with the specified amount of the recom-
mended coolant)
Refer to “CHANGING THE COOLANT” in
chapter 3.

crankcase
(with the specified amount of the recom-
mended engine oil)
Refer to “CHANGING THE ENGINE OIL” in
chapter 3.
4. Check:

cooling system
Leaks
Repair or replace any faulty part.
5. Measure:

radiator cap opening pressure
Below the specified pressure
Replace the
radiator cap.
Refer to “CHECKING THE RADIATOR”.
ProCarManuals.com

6-14
WATER PUMPCOOL
NOTE:
NOTE:
NOTE:
EAS00471
DISASSEMBLING THE WATER PUMP
1. Remove:

water pump seal
1
Tap out the water pump seal from the inside of
the water pump housing.
2Water pump housing
2. Remove:

oil seal
1

bearing 2
Tap out the bearing and oil seal from the outside
of the water pump housing.
3Water pump housing
3. Remove:

rubber damper holder
1

rubber damper 2
(from the impeller, with a thin, flat-head
screwdriver)
Do not scratch the impeller shaft.
EAS00473
CHECKING THE WATER PUMP
1. Check:

water pump housing cover
1

water pump housing 2

impeller 3

rubber damper 4

rubber damper holder 5

water pump seals

oil seal
Cracks / damage / wear
Replace.
2. Check:

bearing
Rough movement
Replace.
3. Check:

water pump outlet pipe
Cracks / damage / wear
Replace.
ProCarManuals.com

7-7
Engine operation is not normal or the engine trouble warning light is on.
* Engine trouble warning light may not come on even if the engine operation is not normal.
The engine trouble warning light comes on.
Check the fault code number displayed on the me-
ter.
Identify the probable cause of malfunction. (Refer
to the “Diagnostic fault code table”.)
Check and repair the probable case of malfunc-
tion.
Fault code No.
appearFault code No.
disappear
Check and repair.
(Refer to “TROU-
BLESHOOTING DE-
TAILS”.)
Monitor the operation
of the sensors and
actuators in the diag-
nostic mode. (Refer
to “Diagnostic mode
table” in chapter 7)Check and repair.
(Refer to “FAIL-SAFE
ACTIONS TABLE”.)
Perform ECU reinstatement action. (Refer to “Re-
instatement method” in “TROUBLESHOOTING
DETAILS”.)
Turn the main switch to “OFF”, turn the main switch
back to “ON”, and then check if the fault code num-
ber is still displayed.
Erasing the malfunction history:*
The malfunction history is stored even if the main
switch is turned OFF.
The malfunction history must be erased in the
diagnostic mode. (Refer to the “Diagnostic mode
table (Diagnostic code No.62)”)Repairs completed
The engine trouble warning light does not come
on.
Check the operation of following sensors and ac-
tuators in the diagnostic mode (Refer to “Diagnos-
tic mode table” in chapter 7.)
Malfunction of en-
gineDefective sensor
or actuator
Check and repair
the inner parts of
engine. (Refer to
Chapter 5)Check and repair
the corresponding
sensor or actua-
tor.
* Operated when the engine trouble warning light is on.
Fault code
number displayed
Fault code number not displayed
OKNG
OK
OK
Check the engine condition.
OK NG
01: Throttle position
sensor (throttle
angle)
03: Intake air pressure
07: Vehicle speed pulse
09: Fuel system volt-
age (battery bolt)
21: Neutral switch
30: Ignition coil #1
31: Ignition coil #232: Ignition coil #3
33: Ignition coil #4
36: Injector #1
37: Injector #2
38: Injector #3
39: Injector #4
48: Al system solenoid
53: EXUP servo motor
56: Sub-throttle servo
motor
FUEL INJECTION SYSTEMFI
EAS00904
TROUBLESHOOTING CHART
ProCarManuals.com

7-12
FUEL INJECTION SYSTEMFI
NOTE: Diagnostic mode table
Switch the meter display from the regular mode to the diagnosis mode. To switch the display, refer to
“DIAGNOSTIC MODE”.

Check the intake air temperature and coolant temperature as close as possible to the intake air tem-
perature sensor and the coolant temperature sensor respectively.

If it is not possible to check it with an atmospheric pressure gauge, judge it by using 101.3 kPa as the
standard.

If it is not possible to check the intake air temperature, use the ambient temperature as reference.
Diagnostic
codeItemDescription of actionData displayed on meter
(reference value)
01
Throttle angleDisplays the throttle angle.

Check with throttle fully closed.

Check with throttle fully open.0
125 degrees

Fully closed position (15
18)

Fully open position (95
100)
02
Atmospheric
pressureDisplays the atmospheric pressure.
* Use an atmospheric pressure gauge to check the
atmospheric pressure.Compare it to the value
displayed on the meter.
03
Intake air pressureDisplays the intake air pressure.
Engine stop switch is on.
* Generate the pressure difference by cranking the engine
with the starter, without actually starting the engine.
Not cranking-atmospheric
pressure

Cranking-intake air pressure It
changes at the value whitch is
smaller than in the atomo-
spheric pressure.
05Intake temperatureDisplays the intake air temperature.
* Check the temperature in the air cleaner case.Compare it to the value
displayed on the meter.
06Coolant temperatureDisplays the coolant temperature.
* Check the temperature of the coolant.Compare it to the value
displayed on the meter.
07
Vehicle speed pulseDisplays the accumulation of the vehicle pulses that are
generated when the tire is spun.(0
999; resets to 0 after 999)
OK if the numbers appear on
the meter.
08Lean angle cut-off
switchDisplays the lean angle cut-off switch values.Upright: 0.4
1.4 V
Overturned: 3.7
4.4 V
09Fuel system voltage
(battery voltage)Displays the fuel system voltage (battery voltage).
Engine stop switch is on.0
18.7 V
Normally, approximately 12.0 V
20Sidestand switchDisplays that the switch is ON or OFF. (When the gear is in a
position other than neutral.)Stand retracted: ON
Stand extended: OFF
21Neutral switchDisplays that the switch is ON or OFF.Neutral: ON
In gear: OFF
30
Ignition coil #1After the engine stop switch has been turned from OFF to
ON, it actuates ignition coil #1 for five times every second
and illuminates the engine trouble warning light.
* Connect an ignition checker.
* If the engine stop switch is ON, turn it OFF once, and then
turn it back ON.Check that spark is generated,
5 times with the engine stop
switch ON.
31
Ignition coils #2After the engine stop switch has been turned from OFF to
ON, it actuates ignition coil #2 for five times every second
and illuminates the engine trouble warning light.
* Connect an ignition checker.
* If the engine stop switch is ON, turn it OFF once, and then
turn it back ON.Check that spark is generated,
5 times with the engine stop
switch ON.
ProCarManuals.com

7-13
FUEL INJECTION SYSTEMFI
Diagnostic
codeItemDescription of actionData displayed on meter
(reference value)
32
Ignition coil #3After the engine stop switch has been turned from OFF to
ON, it actuates ignition coil #3 for five times every second
and illuminates the engine trouble warning light.
* Connect an ignition checker.
* If the engine stop switch is ON, turn it OFF once, and then
turn it back ON.Check that spark is generated,
5 times with the engine stop
switch ON.
33
Ignition coil #4After the engine stop switch has been turned from OFF to
ON, it actuates ignition coil #4 for five times every second
and illuminates the engine trouble warning light.
* Connect an ignition checker.
* If the engine stop switch is ON, turn it OFF once, and then
turn it back ON.Check that spark is generated,
5 times with the engine stop
switch ON.
36
Injector #1After the engine stop switch has been turned from OFF to
ON, it actuates the injector #1 five times every second and
illuminates the engine trouble warning light.
* If the engine stop switch is ON, turn it OFF once, and then
turn it back ON.Check the operating sound of
the injector five times with
engine stop switch ON.
37
Injector #2After the engine stop switch has been turned from OFF to
ON, it actuates the injector #2 five times every second and
illuminates the engine trouble warning light.
* If the engine stop switch is ON, turn it OFF once, and then
turn it back ON.Check the operating sound of
the injector five times with
engine stop switch ON.
38
Injector #3After the engine stop switch has been turned from OFF to
ON, it actuates the injector #3 five times every second and
illuminates the engine trouble warning light.
* If the engine stop switch is ON, turn it OFF once, and then
turn it back ON.Check the operating sound of
the injector five times with
engine stop switch ON.
39
Injector #4After the engine stop switch has been turned from OFF to
ON, it actuates the injector #4 five times every second and
illuminates the engine trouble warning light.
* If the engine stop switch is ON, turn it OFF once, and then
turn it back ON.Check the operating sound of
the injector five times with
engine stop switch ON.
48
AI system solenoidAfter the engine stop switch has been turned from OFF to
ON, it actuates the AI system solenoid five times every
second and illuminates the engine trouble warning light.
* If the engine stop switch is ON, turn it OFF once, and then
turn it back ON.Check the operating sound of
the AI system solenoid 5 times
with the engine stop
switch ON.
50
Fuel injection system
relayAfter the engine stop switch has been turned from OFF to
ON, it actuates the fuel injection system relay five times
every second and illuminates the engine trouble warning
light (the light is OFF when the relay is ON, and the light is
ON when the relay is OFF).
* If the engine stop switch is ON, turn it OFF once, and then
turn it back ON.Check the fuel injection system
relay operating sound 5 times
with the engine stop
switch ON.
51
Radiator fan motor
relayAfter the engine stop switch has been turned from OFF to
ON, it actuates the radiator fan motor relay five times every
5 seconds and illuminates the engine trouble warning light.
(ON 2 seconds, OFF 3 seconds)
* If the engine stop switch is ON, turn it OFF once, and then
turn it back ON.Check the radiator fan motor
relay operating sound 5 times
with the engine stop
switch ON.
(At that time, the fan motor
rotates.)
ProCarManuals.com

7-27
FUEL INJECTION SYSTEMFIFUEL INJECTION SYSTEMFI
Fault code No.33SymptomMalfunction detected in the primary lead of the ignition coil (#1).
Used diagnostic code No. 30 (ignition coil #1)
OrderInspection operation item and probable
causeOperation item and countermeasureReinstatement
method
1Connected condition of connector
Inspect the coupler for any pins that
may have pulled out.
Check the locking condition of the
coupler.If there is a malfunction, repair it and connect it
securely.
Ignition coil primary side coupler – Orange
Main wiring harness ECU couplerReinstated by
starting the en-
gine and oper-
ating it at idle.
2Open or short circuit in lead.Repair or replace if there is an open or short
circuit.
Between ignition coil coupler (#1) and ECU
coupler / main harness
Orange – Orange
Red / Black – Red / Black
3Detective ignition coil (test the primary
and secondary coils for continuity).Execute the diagnostic mode (Code No.30).
Replace if defective.
Refer to “IGNITION SYSTEM” in chapter 8.
Fault code No.34SymptomMalfunction detected in the primary lead of the ignition coil (#2).
Used diagnostic code No. 31 (ignition coil #2)
OrderInspection operation item and probable
causeOperation item and countermeasureReinstatement
method
1Connected condition of connector
Inspect the coupler for any pins that
may have pulled out.
Check the locking condition of the
coupler.If there is a malfunction, repair it and connect it
securely.
Ignition coil primary side coupler – Gray / Red
Main wiring harness ECU couplerReinstated by
starting the en-
gine and oper-
ating it at idle.
2Open or short circuit in lead wire.Repair or replace if there is an open or short
circuit.
Between ignition coil coupler (#2) and ECU
coupler / main harness
Gray / Red – Gray / Red
Red / Black – Red / Black
3Defective ignition coil (test the primary
and secondary coils for continuity).Execute the diagnostic mode (Code No.31).
Replace if defective.
Refer to “IGNITION SYSTEM” in chapter 8.
Fault code No.35SymptomMalfunction detected in the primary lead of the ignition coil (#3).
Used diagnostic code No. 32 (ignition coil #3)
OrderInspection operation item and probable
causeOperation item and countermeasureReinstatement
method
1Connected condition of connector
Inspect the coupler for any pins that
may have pulled out.
Check the locking condition of the
coupler.If there is a malfunction, repair it and connect it
securely.
Ignition coil primary side coupler – Orange /
Green
Main wiring harness ECU couplerReinstated by
starting the en-
gine and oper-
ating it at idle.
2Open or short circuit in lead wire.Repair or replace if there is an open or short
circuit.
Between ignition coil coupler (#3) and ECU
coupler / main harness
Orange / Green – Orange / Green
Red / Black – Red / Black
3Defective ignition coil (test the primary
and secondary coils for continuity).Execute the diagnostic mode (Code No.32).
Replace if defective.
Refer to “IGNITION SYSTEM” in chapter 8.
ProCarManuals.com

7-28
FUEL INJECTION SYSTEMFI
Fault code No.36SymptomMalfunction detected in the primary lead of the ignition coil (#4).
Used diagnostic code No. 33 (ignition coil #4)
OrderInspection operation item and probable
causeOperation item and countermeasureReinstatement
method
1Connected state of connector
Inspect the coupler for any pins that
may have pulled out.
Check the locking condition of the
coupler.If there is a malfunction, repair it and connect it
securely.
Ignition coil primary side coupler – Gray / Green
Main wiring harness ECU couplerReinstated by
starting the en-
gine and oper-
ating it at idle.
2Open or short circuit in lead wire.Repair or replace if there is an open or short
circuit.
Between ignition coil coupler (#4) and ECU
coupler / main harness
Gray / Green – Gray / Green
Red / Black – Red / Black
3Defective ignition coil (test the primary
and secondary coils for continuity).Execute the diagnostic mode (Code No.33).
Replace if defective.
Refer to “IGNITION SYSTEM” in chapter 8.
Fault code No.41SymptomOpen or short circuit detected in the lean angle cut-off switch.
Used diagnostic code No. 08 (lean angle cut-off switch)
OrderInspection operation item and probable
causeOperation item and countermeasureReinstatement
method
1Connected condition of connector
Inspect the coupler for any pins that
may have pulled out.
Check the locking condition of the
coupler.If there is a malfunction, repair it and connect it
securely.
Lean angle cut-off switch coupler
Main wiring harness ECU couplerReinstated by
turning the
main switch
ON.
2Open or short circuit in wiring harness.Repair or replace if there is an open or short
circuit.
Between switch coupler and ECU coupler
Black / Blue – Black / Blue
Yellow / Green – Yellow / Green
Blue – Blue
3Defective lean angle cut-off switchExecute the diagnostic mode (Code No.08).
Replace if defective.
Refer to Fault code No. 30.
ProCarManuals.com

8-4
11Neutral switch
12Rear brake light switch
13Fuse box
1Main switch
2Horn switch
3Dimmer switch
4Turn signal switch
5Clutch switch
6Sidestand switch
7Engine stop switch
8Front brake light switch
9Start switch
10Oil level switch
CHECKING THE SWITCHESELEC
EAS00731
CHECKING THE SWITCHES
Check each switch for damage or wear, proper connections, and also for continuity between the termi-
nals. Refer to “CHECKING SWITCH CONTINUITY”.
Damage / wear
Repair or replace.
Improperly connected
Properly connect.
Incorrect continuity reading
Replace the switch.
ProCarManuals.com