coolant YAMAHA YZF-R1S 2004 Service Manual

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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1-2
1
1 Clock
2 Speedometer
3 “SELECT” button
4 “RESET” button
5 Tachometer
6 Coolant temperature display / air intake
temperature display
7 Odometer / tripmeters / fuel reserve tripme-
ter / stopwatch
8 Shift timing indicator light
1 Clock
2 Speedometer
FEATURES
GEN
INFO
NOTE:
EAS00019
FEATURES
INSTRUMENT FUNCTIONS
Multi-function display
The multi-function meter unit is equipped with
the following:

a speedometer (which shows the riding
speed)

a tachometer (witch shows engine speed)

an odometer (which shows the total distance
traveled)

two tripmeters (which show the distance
traveled since they were last set to zero)

a fuel reserve tripmeter (which shows the
distance traveled since the fuel level warning
light came on)

a stopwatch

a clock

a coolant temperature display

an air intake temperature display

a self-diagnosis device

a display brightness and shift timing indicator
light control mode

Be sure to turn the key to “ON” before using the “SELECT” and “RESET” buttons.
Clock mode
Turn the key to “ON”.
To set the clock
1. Push the “SELECT” button and “RESET”
button together for at least two seconds.
2. When the hour digits start flashing, push the
“RESET” button to set the hours.
3. Push the “SELECT” button, and the minute
digits will start flashing.
4. Push the “RESET” button to set the minutes.
5. Push the “SELECT” button and then release
it to start the clock.
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1-3
FEATURES
GEN
INFO
1 Coolant temperature display / air intake
temperature display
2 Odometer / tripmeters / fuel reserve tripme-
ter / stopwatch
3 Shift timing indicator light
NOTE:
NOTE:Odometer, tripmeter, and stopwatch modes
Push the “SELECT” button to switch the display
between the odometer mode “ODO”, the trip-
meter modes “TRIP A” and “TRIP B” and the
stopwatch mode in the following order:
TRIP A
TRIP B
ODO
Stopwatch

TRIP A
If the fuel level warning light comes on, the
odometer display will automatically change to
the fuel reserve tripmeter mode ”F-TRIP” and
start counting the distance traveled from that
point. In that case, push the ”SELECT” button to
switch the display between the various tripme-
ter, odometer, and stopwatch modes in the fol-
lowing order:
F-TRIP
Stopwatch
TRIP A
TRIP B

ODO
F-TRIP
To reset a tripmeter, select it by pushing the “SE-
LECT” button, and then push the “RESET” button
for at least one second. If you do not reset the fuel
reserve tripmeter manually, it will reset itself auto-
matically and the display will return to the prior
mode after refueling and traveling 5 km (3 mi).
Stopwatch mode
Standard measurement
1. Push the “RESET” button to start the stopwatch.
2. Push the “SELECT” button to stop the stopwatch.
3. Push the “SELECT” button again to reset the stopwatch.
Split-time measurement
1. Push the “RESET” button to start the stopwatch.
2. Push the “RESET” button to measure split-times. (The colon “:” will start flashing.)
3. Push the “RESET” button to display the final split-time or push the “SELECT” button to stop the stop-
watch and display total elapsed time.
4. Push the “SELECT” button to reset the stopwatch.
Coolant temperature display
The coolant temperature display indicates the temperature of the coolant. Push the “RESET” button to
switch the coolant temperature display to the air intake temperature display.
When the coolant temperature display is selected, “C” is displayed before the coolant temperature.
Air intake temperature display
The air intake temperature display indicates the temperature of the air drawn into the air filter case. Push
the “RESET” button to switch the coolant temperature display to the air intake temperature display.

Even if the air intake temperature is set to be displayed, the coolant temperature warning light comes
on when the engine overheats.

When the key is turned to “ON”, the coolant temperature is automatically displayed, even if the air
intake temperature was displayed prior to turning the key to “OFF”.

When the air intake temperature display is selected, “A” is displayed before thetemperature.
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2-3
ENGINE SPECIFICATIONSSPEC
ItemStandardLimit
Oil filter
Oil filter type
Bypass valve opening pressure
Paper
80  120 kPa (0.8  1.2 kg / cm2,
0.8  1.2 bar, 11.6  17.4 psi)








Oil pump
Oil pump type
Inner-rotor-to-outer-rotor-tip
clearance
Outer-rotor-to-oil-pump-housing
clearance
Trochoid
0.01  0.10 mm
(0.0004  0.0039 in)
0.09  0.15 mm
(0.00035  0.0059 in)



0.18 mm
(0.0071 in)
0.22 mm
(0.0087 in)
Cooling system
Radiator capacity
Radiator cap opening pressure
Radiator core
Width
Height
Depth
Coolant reservoir
Capacity
Water pump
Water pump type
Reduction ratio
Max. impeller shaft tilt
2.51 L (2.21 Imp qt, 2.65 US qt)
108  137 kPa (1.08  1.37 kg / cm2,
1.0  1.3 bar, 15.6  19.9 psi)
380 mm (14.96 in)
258 mm (10.2 in)
24 mm (0.94 in)
0.25 L (0.22 Imp qt, 0.26 US qt)
Single suction centrifugal pump
65 / 43
25 / 32 (1.181)































0.15 mm
(0.006 in)
Starting system typeElectric starter
Spark plugs
Model (manufacturer)
quantity
Spark plug gap
CR9EK (NGK)
4
0.6  0.7 mm (0.0236  0.0276 in)







Cylinder head
Volume
Max. warpage
12.5  13.1 cm3 (0.76  0.80 cu.in)







0.10 mm
(0.0039 in)
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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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2-21
TIGHTENING TORQUESSPEC
NOTE 1:
NOTE 2:
ItemFastenerThreadQ’tyTightening torqueRemarksItemFastenersizeQtyNmm
kgft
lbRemarks
Main axle bearing housingBoltM63121.28.7
Shift fork shaft stopperBoltM62101.07.2
Stopper screwScrewM81222.216
Shift rod lock nut (rear)NutM6170.75.0Left thread
Shift rod lock nut (front)NutM6170.75.0
Shift rod jointBoltM61101.07.2
Shift armBoltM61101.07.2
E.C.U.ScrewM6270.75.0
Neutral switch—M101202.015
EXUP servo motor coverScrewM5220.21.5
Coolant temperature sensor—M121181.813
Cylinder identification sensorBoltM6180.85.7
Atmospheric pressure sensorScrewM5270.75.0
Crankshaft position sensorBoltM61101.07.2
Oil level switchBoltM62101.07.2
1. First, tighten the bolts to approximately 19 Nm (1.9 m
kg, 14 ft
lb) with a torque wrench following the
tightening order.
2. Retighten the bolts 67 Nm (6.7 m
kg, 48 ft
lb) with a torque wrench.
1. First, tighten the bolts to approximately 20 Nm (2.0 m
kg, 15 ft
lb) with a torque wrench following the
tightening order.
2. Loosen the all bolts one by one following the tightening order and then tighten them to 20 Nm (2.7
m
kg, 15 ft
lb) again.
3. Retighten the bolts further to reach the specified angle (60).
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2-23
TIGHTENING TORQUESSPEC
See NOTE 2 CHASSIS TIGHTENING TORQUES
ItemThreadTighteningRemarksItemsizeNmm
kgft
lbRemarks
Upper bracket and outer tubeM8262.619
Upper bracket and steering stem nutM2811 311.382
Handlebar and outer tubeM8171.712
Handlebar and upper bracketM6131.39
Steering shaft and ring nutM30181.813See NOTE 1
Outer tube and under bracketM8232.317
Main switch and upper bracketM8262.619
Front brake master cylinder cap stopperM41.20.120.9
Front brake hose union boltsM10303.022
Front brake master cylinder and bracketM6131.39
Meter assembly and front cowling stay—1.30.130.9
Headlight and front cowling stay—0.80.080.6
Front cowling and headlight assembly—1.50.151.1
Cover 7, 8 and frameM650.53.6
Under cowling and engineM650.53.6
Windshield and front cowlingM50.40.040.3
Duct and console panelM51.30.130.9
End grip and handlebarM640.42.9
Horn bracket and under bracketM640.42.9
Coolant reservoir tank and frameM650.53.6
Engine mount front (left and right)M10454.533
Engine mount rear upperM10515.137
Engine mount rear underM10515.137
Engine mount rear adjust boltM1670.75.1
Catalyst pipe stay and frameM10444.432
Clutch cable lock nut (engine side)M870.75.1
Main frame and rear frameM10414.130
Throttle cable adjust nut (throttle body side)M650.53.6
Cover 2 and plate—0.80.080.6
Pivot shaft and nutM1810510.576
Connecting rod and frameM10444.432
Relay arm and connecting rodM10444.432
Relay arm and swingarmM10444.432
Rear shock absorber and relay armM10444.432
Rear shock absorber and upper bracketM10444.432
Upper bracket and frameM14929.267
Seal guardM670.75.1
Drive chain caseM670.75.1
Chain puller adjust nutM8161.612
Fuel tank and fuel pump assemblyM540.42.9
Fuel tank stay (front side) and frameM670.75.1
Fuel tank and fuel tank stay (front side)M670.75.1
Fuel tank stay (rear side) and rear frameM670.75.1
Side cover and fuel tankM50.40.040.3
Rider seat and frameM670.75.1
Seat lock plate and rear frameM6101.07
Side cover (rear side) and frameM540.42.9
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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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2-40
P To the air filter
Q Route the fuel tank drain hose
over the canister stay and be-
tween the breather hose 2 and
wire harness. On the front side of
the canister stay, let though the
bottom of the A.C.magneto lead
and the wire harness.
R Route by the upside of vehicle
away from the canister stay.
CABLE ROUTINGSPEC
I The coupler for the air induction
solenoid lead and camshaft sen-
sor lead should be connected
above the ignition coil sub wire
harness and it should not drop
on the cylinder head cover be-
hind the ignition coil.
J Pass the right handlebar switch
lead between the frame and heat
protector.
K Coolant reservoir tank drain
hose should cross with the
speed sensor lead under the
swingarm bracket. Route the
coolant reservoir tank drain hose
over the up side of the vehicle.L Pass the rear brake light switch
lead between the swingarm
bracket and coolant reservoir
tank.
M Release the tip of the clamp and
install it to the clutch cable.
Insert the clamp to the hole lo-
cated on the right back side of
the radiator.
Radiator fan motor lead should
not be caught while inserting the
clamp.
N Push the clamp until it hits the ra-
diator side stay. Radiator fan mo-
tor lead should not be caught.
O Clamp the clutch cable so that it
is within this specified clamp.
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2-41
C Fold back the clamp and secure
it after passing the lead through
the clamp.
D To the EXUP servo motor
E Pass the coolant reservoir tank
drain hose and fuel tank drain
hose through the clamp from the
outer side of the water pump inlet
pipe after routing it behind the
water pump breather hose.
The lengths of two hose ends are
allowed to be random. Any direc-
tion of cut edges can be ac-
cepted. (Only for the fuel tank
drain hose)
F Clamp the fuel tank drain hose
and fuel tank breather hose.A Clamp the leads so that they are
positioned inner of the vehicle
than the washer position after
routing them between the frame
and radiator stay. Align the clamp
position with the taping sections
of leads. Point the tip of the clamp
(surplus section) to the down
front side of the vehicle.
What the clamp fastens at this
stage are the handlebar switch
and main switch leads.
B Pass the main switch lead and
left handlebar switch lead be-
tween the frame and the heat
protector.
CABLE ROUTINGSPEC
1Heat protector
2Main switch lead
3Left handlebar switch lead
4EXUP servo motor lead
5Coolant reservoir tank drain hose
6Fuel tank drain hose
7Coolant outlet pipe
8Sidestand switch lead
9Oil level switch lead
10A.C.magneto lead
11Fuse box stay
12Water hose
13Stay 1
14Chain case cover
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