checking oil YAMAHA YZF-R1S 2004 Service Manual

CHAPTER 1
GENERAL INFORMATION
MOTORCYCLE IDENTIFICATION1-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
VEHICLE IDENTIFICATION NUMBER 1-1. . . . . . . . . . . . . . . . . . . . . . . .
MODEL LABEL 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FEATURES1-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTRUMENT FUNCTIONS 1-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
IMPORTANT INFORMATION1-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PREPARATION FOR REMOVAL AND DISASSEMBLY 1-6. . . . . . . . .
REPLACEMENT PARTS 1-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GASKETS, OIL SEALS AND O-RINGS 1-6. . . . . . . . . . . . . . . . . . . . . . .
LOCK WASHERS / PLATES AND COTTER PINS 1-7. . . . . . . . . . . . . .
BEARINGS AND OIL SEALS 1-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CIRCLIPS 1-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE CONNECTIONS1-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIAL TOOLS1-9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHAPTER 2
SPECIFICATIONS
GENERAL SPECIFICATIONS2-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE SPECIFICATIONS2-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHASSIS SPECIFICATIONS2-11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ELECTRICAL SPECIFICATIONS2-15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONVERSION TABLE2-18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL TIGHTENING TORQUE SPECIFICATIONS2-18 . . . . . . . . . . . .
TIGHTENING TORQUES2-19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE TIGHTENING TORQUES 2-19. . . . . . . . . . . . . . . . . . . . . . . . . . .
CHASSIS TIGHTENING TORQUES 2-23. . . . . . . . . . . . . . . . . . . . . . . . . .
LUBRICATION POINTS AND LUBRICANT TYPES2-25 . . . . . . . . . . . . . . .
ENGINE 2-25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHASSIS 2-26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
COOLING SYSTEM DIAGRAMS2-27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE OIL LUBRICATION CHART2-29 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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LUBRICATION DIAGRAMS2-30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CABLE ROUTING2-35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHAPTER 3
PERIODIC CHECKS AND ADJUSTMENTS
INTRODUCTION3-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PERIODIC MAINTENANCE CHART FOR THE EMISSION
CONTROL SYSTEM3-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL MAINTENANCE AND LUBRICATION CHART3-1 . . . . . . . . .
SEATS3-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FUEL TANK3-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE FUEL TANK 3-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE FUEL PUMP 3-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE FUEL PUMP 3-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE FUEL TANK 3-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
COWLINGS3-7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FRONT COWLING AND SIDE COWLINGS 3-7. . . . . . . . . . . . . . . . . . .
REAR COWLING 3-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVAL 3-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLATION 3-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AIR FILTER CASE3-10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE3-11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ADJUSTING THE VALVE CLEARANCE 3-11. . . . . . . . . . . . . . . . . . . . . .
SYNCHRONIZING THE THROTTLE BODIES 3-17. . . . . . . . . . . . . . . . .
ADJUSTING THE EXHAUST GAS VOLUME 3-19. . . . . . . . . . . . . . . . . .
ADJUSTING THE ENGINE IDLING SPEED 3-21. . . . . . . . . . . . . . . . . . .
ADJUSTING THE THROTTLE CABLE FREE PLAY 3-22. . . . . . . . . . . .
CHECKING THE SPARK PLUGS 3-23. . . . . . . . . . . . . . . . . . . . . . . . . . . .
MEASURING THE COMPRESSION PRESSURE 3-24. . . . . . . . . . . . . .
CHECKING THE ENGINE OIL LEVEL 3-26. . . . . . . . . . . . . . . . . . . . . . . .
CHANGING THE ENGINE OIL 3-28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MEASURING THE ENGINE OIL PRESSURE 3-29. . . . . . . . . . . . . . . . .
ADJUSTING THE CLUTCH CABLE FREE PLAY 3-31. . . . . . . . . . . . . . .
REPLACING THE AIR FILTER ELEMENT 3-32. . . . . . . . . . . . . . . . . . . .
CHECKING THE FUEL AND BREATHER HOSES 3-33. . . . . . . . . . . . .
CHECKING THE CRANKCASE BREATHER HOSE 3-34. . . . . . . . . . . .
CHECKING THE EXHAUST SYSTEM 3-35. . . . . . . . . . . . . . . . . . . . . . . .
ADJUSTING THE EXUP CABLES 3-36. . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE COOLANT LEVEL 3-37. . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE COOLING SYSTEM 3-38. . . . . . . . . . . . . . . . . . . . . . . .
CHANGING THE COOLANT 3-39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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STARTER CLUTCH AND GENERATOR5-35 . . . . . . . . . . . . . . . . . . . . . . . . .
STATOR COIL ASSEMBLY 5-35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STARTER CLUTCH 5-37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE GENERATOR 5-38. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE STARTER CLUTCH 5-39. . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE DAMPER 5-39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE STARTER CLUTCH 5-40. . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE STARTER CLUTCH 5-41. . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE GENERATOR 5-41. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CRANKSHAFT POSITION SENSOR5-43 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE CRANKSHAFT POSITION SENSOR 5-44. . . . . . . . .
INSTALLING THE CRANKSHAFT POSITION SENSOR 5-44. . . . . . . .
CLUTCH5-46 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CLUTCH COVER 5-46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PULL LEVER SHAFT 5-47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CLUTCH 5-48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE CLUTCH 5-50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE FRICTION PLATES 5-52. . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE CLUTCH PLATES 5-52. . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE CLUTCH SPRINGS 5-53. . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE CLUTCH HOUSING 5-53. . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE CLUTCH BOSS 5-53. . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE PRESSURE PLATE 5-54. . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE PULL LEVER SHAFT AND PULL ROD 5-54. . . . . . .
INSTALLING THE CLUTCH 5-54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SHIFT SHAFT5-58 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SHIFT SHAFT AND STOPPER LEVER 5-58. . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE SHIFT SHAFT 5-60. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE SHIFT SHAFT 5-61. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE STOPPER LEVER 5-61. . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE SHIFT SHAFT 5-61. . . . . . . . . . . . . . . . . . . . . . . . . . . .
OIL PAN AND OIL PUMP5-63 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE OIL PAN 5-66. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE SPROCKET AND CHAIN 5-66. . . . . . . . . . . . . . . . . . . .
CHECKING THE OIL PUMP 5-67. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE RELIEF VALVE 5-67. . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE OIL DELIVERY PIPE AND OIL PIPE 5-68. . . . . . . . .
CHECKING THE OIL STRAINER 5-68. . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE OIL NOZZLES 5-68. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ASSEMBLING THE OIL PUMP 5-68. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE OIL / WATER PUMP ASSEMBLY 5-69. . . . . . . . . . . .
INSTALLING THE OIL PAN 5-71. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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CRANKCASE5-72 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DISASSEMBLING THE CRANKCASE 5-74. . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE CRANKCASE 5-75. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE BEARINGS AND OIL SEALS 5-75. . . . . . . . . . . . . . . .
ASSEMBLING THE CRANKCASE 5-75. . . . . . . . . . . . . . . . . . . . . . . . . . .
CONNECTING RODS AND PISTONS5-77 . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE CONNECTING RODS AND PISTONS 5-78. . . . . . . .
REMOVING THE CRANKSHAFT ASSEMBLY 5-79. . . . . . . . . . . . . . . . .
CHECKING THE CYLINDER AND PISTON 5-79. . . . . . . . . . . . . . . . . . .
CHECKING THE PISTON RINGS 5-80. . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE PISTON PINS 5-81. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE BIG END BEARINGS 5-82. . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE CONNECTING ROD AND PISTON 5-86. . . . . . . . . .
CRANKSHAFT5-92 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE CRANKSHAFT 5-93. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE CRANKSHAFT DRIVE SPROCKET 5-93. . . . . . . . . .
CHECKING THE CRANKSHAFT JOURNAL BEARINGS 5-93. . . . . . . .
INSTALLING THE CRANKSHAFT 5-96. . . . . . . . . . . . . . . . . . . . . . . . . . . .
TRANSMISSION5-97 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TRANSMISSION, SHIFT DRUM ASSEMBLY AND
SHIFT FORKS 5-97. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE TRANSMISSION 5-103. . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE SHIFT FORKS 5-103. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE SHIFT DRUM ASSEMBLY 5-104. . . . . . . . . . . . . . . . . . .
CHECKING THE TRANSMISSION 5-104. . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE TRANSMISSION 5-105. . . . . . . . . . . . . . . . . . . . . . . . . .
CHAPTER 6
COOLING SYSTEM
RADIATOR6-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE RADIATOR 6-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE RADIATOR 6-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OIL COOLER6-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE OIL COOLER 6-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE OIL COOLER 6-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
THERMOSTAT6-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE THERMOSTAT 6-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ASSEMBLING THE THERMOSTAT ASSEMBLY 6-11. . . . . . . . . . . . . . .
INSTALLING THE THERMOSTAT ASSEMBLY 6-11. . . . . . . . . . . . . . . .
WATER PUMP6-12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
IMPELLER SHAFT 6-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DISASSEMBLING THE WATER PUMP 6-14. . . . . . . . . . . . . . . . . . . . . . .
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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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3-23
CHECKING THE SPARK PLUGS
CHK
ADJ
CAUTION:
EAS00059
CHECKING THE SPARK PLUGS
The following procedure applies to all of the
spark plugs.
1. Remove:

side cowlings

bottom cowlings
Refer to “COWLINGS”.
2. Remove:

radiator upper bolts

radiator lower bolt
Refer to “RADIATOR” in chapter 6.
3. Remove:

ignition coils

spark plugs
Before removing the spark plugs, blow away
any dirt accumulated in the spark plug wells
with compressed air to prevent it from fal-
ling into the cylinders.
4. Check:

spark plug type
Incorrect
Change.
Spark plug type (manufacturer)
CR9EK (NGK)
5. Check:

electrode
1
Damage / wear
Replace the spark plug.

insulator
2
Abnormal color
Replace the spark plug.
Normal color is medium-to-light tan.
6. Clean:

spark plug
(with a spark plug cleaner or wire brush)
7. Measure:

spark plug gap
a
(with a wire Thickness gauge)
Out of specification
Regap.
Spark plug gap
0.6  0.7 mm
(0.0236  0.0276 in)
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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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3-26
MEASURING THE COMPRESSION PRESSURE /
CHECKING THE ENGINE OIL LEVELCHK
ADJ
13 Nm (1.3 m
kg, 9.4 ft
lb)
NOTE: d. If the compression pressure is below the
minimum specification, pour a teaspoonful of
engine oil into the spark plug bore and mea-
sure again.
Refer to the following table.
Compression pressure
(with oil applied into the cylinder)
ReadingDiagnosis
Higher than
without oilPiston ring(s) wear
or damage

Repair.
Same as without
oilPiston, valves,
cylinder head
gasket or piston
possibly defective

Repair.
6. Install:

spark plug
7. Install:

ignition coils
EAS00069
CHECKING THE ENGINE OIL LEVEL
1. Stand the motorcycle on a level surface.

Place the motorcycle on a suitable stand.

Make sure the motorcycle is upright.
2. Start the engine, warm it up for several min-
utes, and then turn it off.
3. Check:

engine oil level
The engine oil level should be between the
minimum level mark
a and maximum level
mark
b.
Below the minimum level mark
Add the
recommended engine oil to the proper level.
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3-27
CHECKING THE ENGINE OIL LEVEL
CHK
ADJ
NOTE:
NOTE:Recommended oil
AT 5C (40F) or higher
A
Yamalube 4 (20W40) or
SAE 20W40 type SE motor
oil
AT 1 5C (60F) or lower
B
Yamalube 4 (10W30) or
SAE 10W30 type SE motor
oil
Before checking the engine oil level, wait a few
minutes until the oil has settled.
4. Start the engine, warm it up for several min-
utes, and then turn it off.
5. Check the engine oil level again.
Before checking the engine oil level, wait a few
minutes until the oil has settled.
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3-38
CHECKING THE COOLING SYSTEM
CHK
ADJ
EAS00104
CHECKING THE COOLING SYSTEM
1. Remove:

bottom cowlings

side cowlings
Refer to “COWLINGS”.
2. Check:

radiator
1

radiator inlet hose 2

radiator outlet hose 3

oil cooler 4

oil cooler inlet hose 5

oil cooler outlet hose 6

water jacket joint 7

water jacket joint inlet hose 8

water pump inlet pipe 9

water pump outlet pipe 10
Cracks / damage
Replace.
Refer to “COOLING SYSTEM” in chapter 6.
3. Install:

side cowlings

bottom cowling
Refer to “COWLINGS”.
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