headlight bulb YAMAHA YZF-R1S 2004 Service Manual

CHASSIS3-42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ADJUSTING THE FRONT BRAKE 3-42. . . . . . . . . . . . . . . . . . . . . . . . . . .
ADJUSTING THE REAR BRAKE 3-43. . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE BRAKE FLUID LEVEL 3-44. . . . . . . . . . . . . . . . . . . . . .
ADJUSTING THE REAR BRAKE LIGHT SWITCH 3-45. . . . . . . . . . . . .
CHECKING THE FRONT AND REAR BRAKE PADS 3-45. . . . . . . . . . .
CHECKING THE FRONT AND REAR BRAKE HOSES 3-46. . . . . . . . .
BLEEDING THE HYDRAULIC BRAKE SYSTEM 3-47. . . . . . . . . . . . . . .
ADJUSTING THE SHIFT PEDAL 3-48. . . . . . . . . . . . . . . . . . . . . . . . . . . .
ADJUSTING THE DRIVE CHAIN SLACK 3-49. . . . . . . . . . . . . . . . . . . . .
LUBRICATING THE DRIVE CHAIN 3-50. . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING AND ADJUSTING THE STEERING HEAD 3-51. . . . . . . . .
CHECKING THE FRONT FORK 3-53. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ADJUSTING THE FRONT FORK LEGS 3-54. . . . . . . . . . . . . . . . . . . . . .
ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY 3-56. . . . .
CHECKING THE TIRES 3-58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE WHEELS 3-60. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING AND LUBRICATING THE CABLES 3-61. . . . . . . . . . . . . . .
LUBRICATING THE LEVERS AND PEDALS 3-61. . . . . . . . . . . . . . . . . .
LUBRICATING THE SIDESTAND 3-61. . . . . . . . . . . . . . . . . . . . . . . . . . . .
LUBRICATING THE REAR SUSPENSION 3-61. . . . . . . . . . . . . . . . . . . .
ELECTRICAL SYSTEM3-62 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING AND CHARGING THE BATTERY 3-62. . . . . . . . . . . . . . . . .
CHECKING THE FUSES 3-67. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REPLACING THE HEADLIGHT BULBS 3-69. . . . . . . . . . . . . . . . . . . . . .
ADJUSTING THE HEADLIGHT BEAMS 3-70. . . . . . . . . . . . . . . . . . . . . .
CHAPTER 4
CHASSIS
FRONT WHEEL AND BRAKE DISCS4-1 . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE FRONT WHEEL 4-3. . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE FRONT WHEEL 4-3. . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE BRAKE DISCS 4-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE FRONT WHEEL 4-6. . . . . . . . . . . . . . . . . . . . . . . . . . .
ADJUSTING THE FRONT WHEEL STATIC BALANCE 4-7. . . . . . . . .
REAR WHEEL AND BRAKE DISC4-9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REAR WHEEL 4-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REAR BRAKE DISC AND REAR WHEEL SPROCKET 4-10. . . . . . . . .
REMOVING THE REAR WHEEL 4-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE REAR WHEEL 4-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE REAR WHEEL DRIVE HUB 4-13. . . . . . . . . . . . . . . . .
CHECKING AND REPLACING THE REAR WHEEL
SPROCKET 4-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE REAR WHEEL 4-14. . . . . . . . . . . . . . . . . . . . . . . . . . . .
ADJUSTING THE REAR WHEEL STATIC BALANCE 4-14. . . . . . . . . . .
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ELECTRICAL SYSTEMS 9-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INCORRECT ENGINE IDLING SPEED9-2 . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE 9-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FUEL SYSTEM 9-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ELECTRICAL SYSTEMS 9-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE9-2 . . . . . . . . . . . . .
ENGINE 9-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FUEL SYSTEM 9-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FAULTY GEAR SHIFTING9-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SHIFTING IS DIFFICULT 9-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SHIFT PEDAL DOES NOT MOVE 9-3. . . . . . . . . . . . . . . . . . . . . . . . . . . .
JUMPS OUT OF GEAR 9-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FAULTY CLUTCH9-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CLUTCH SLIPS 9-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CLUTCH DRAGS 9-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OVERHEATING9-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE 9-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
COOLING SYSTEM 9-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FUEL SYSTEM 9-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHASSIS 9-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ELECTRICAL SYSTEMS 9-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OVERCOOLING9-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
COOLING SYSTEM 9-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
POOR BRAKING PERFORMANCE9-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FAULTY FRONT FORK LEGS9-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LEAKING OIL 9-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MALFUNCTION 9-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
UNSTABLE HANDLING9-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FAULTY LIGHTING OR SIGNALING SYSTEM9-6 . . . . . . . . . . . . . . . . . . . .
HEADLIGHT DOES NOT COME ON 9-6. . . . . . . . . . . . . . . . . . . . . . . . . .
HEADLIGHT BULB BURNT OUT 9-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TAIL / BRAKE LIGHT DOES NOT COME ON 9-6. . . . . . . . . . . . . . . . . . .
TAIL / BRAKE LIGHT BULB BURNT OUT 9-6. . . . . . . . . . . . . . . . . . . . . .
TURN SIGNAL DOES NOT COME ON 9-6. . . . . . . . . . . . . . . . . . . . . . . .
TURN SIGNAL BLINKS SLOWLY 9-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TURN SIGNAL REMAINS LIT 9-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TURN SIGNAL BLINKS QUICKLY 9-6. . . . . . . . . . . . . . . . . . . . . . . . . . . .
HORN DOES NOT SOUND 9-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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2-15
ELECTRICAL SPECIFICATIONSSPEC
ELECTRICAL SPECIFICATIONS
ItemStandardLimit
System voltage12 V



Ignition system
Ignition system type
Ignition timing
Crankshaft position sensor
resistance / color
T.C.I. unit model (manufacturer)
DC. T.C.I.
5 BTDC at 1,050 r / min
336  504 Ω at 20C (68F) / Gy-B
F8T822 (MITSUBISHI) (USA)
F8T823 (MITSUBISHI) (CAL)



















Ignition coils
Model (manufacturer)
Minimum ignition spark gap
Primary coil resistance
Secondary coil resistance
F6T558 (MITSUBISHI)
6 mm (0.24 in)
1.19  1.61 Ω at 20C (68F)
8.5  11.5 kΩ at 20C (68F)















Charging system
System type
Model (manufacturer)
Normal output
Stator coil resistance / color
A.C. magneto
F4T850 (MITSUBISHI)
14 V / 560 W at 5,000 r / min
0.14  0.18 Ω at 20C (68F) / W-W















Rectifier / regulator
Regulator type
Model (manufacture)
Semi conductor short circuit
FH011AA (SHINDENGEN)







()
No-load regulated voltage
Rectifier capacity
Withstand voltage
()
14.3  15.1 V
50 A
100 V











Battery
Battery type
Battery voltage / capacity
Specific gravity
Manufacturer
Ten hour rate amperage
YTZ10S
12 V / 8.6 Ah
1.310
YUASA
0.8 A



















Headlight typeHalogen bulb
Bulbs (voltage / wattage
quantity)
Headlight
Auxiliary light
Tail / brake light
Front turn signal light / position light
Rear turn signal light
Licence plate light
Meter light
12 V 55 W
4
12 V 5 W
2
LED
1
12 V 21 W / 5 W
2
12 V 21 W
2
12 V 5 W
1
LED
1



























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3-69
A
A
B
B
B
REPLACING THE HEADLIGHT BULBS
CHK
ADJ
WARNING
EAS00183
REPLACING THE HEADLIGHT BULBS
The following procedure applies to both of the
headlight bulbs.
1. Disconnect:

headlight bulb cover
1

headlight coupler 2
Ahigh beam
Blow beam
2. Remove:

headlight bulb holder
1
Ahigh beam
Blow beam
3. Remove:

headlight bulb
Since the headlight bulb gets extremely hot,
keep flammable products and your hands
away from the bulb until it has cooled down.
4. Install:

headlight bulb
New
Secure the new headlight bulb with the head-
light bulb holder.
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3-70
REPLACING THE HEADLIGHT BULBS /
ADJUSTING THE HEADLIGHT BEAMSCHK
ADJ
CAUTION:
a
b
a
b
Avoid touching the glass part of the head-
light bulb to keep it free from oil, otherwise
the transparency of the glass, the life of the
bulb and the luminous flux will be adversely
affected. If the headlight bulb gets soiled,
thoroughly clean it with a cloth moistened
with alcohol or lacquer thinner.
5. Install:

headlight bulb holder
6. Install:

headlight bulb cover (high beam)

headlight bulb coupler (low beam)
7. Connect:

headlight coupler (high beam)

headlight cover (low beam)
EAS00185
ADJUSTING THE HEADLIGHT BEAMS
The following procedure applies to both of the
headlights.
1. Remove:

front cowling inner panels
Refer to “COWLINGS”.
2. Adjust:

headlight beam (vertically)
a. Turn the adjusting screw
1 in direction a or
b.
Direction
Headlight beam is raised.
DirectionHeadlight beam is
lowered.
3. Adjust:

headlight beam (horizontally)
a. Turn the adjusting screw
2 in direction a or
b.
Direction
Headlight beam moves to
the left.
DirectionHeadlight beam moves to
the right.
4. Install:

front cowling inner panels
Refer to “COWLINGS”.
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8-5
CHECKING THE BULBS AND BULB SOCKETSELEC
WARNING
EAS00732
CHECKING THE BULBS AND
BULB SOCKETS
Check each bulb and bulb socket for damage or
wear, proper connections, and also for continu-
ity between the terminals.
Damage / wear
Repair or replace the bulb,
bulb socket or both.
Improperly connected
Properly connect.
No continuity
Repair or replace the bulb, bulb
socket or both.
TYPES OF BULBS
The bulbs used on this motorcycle are shown in
the illustration on the left.

Bulbs
A and B are used for the headlights
and usually use a bulb holder that must be
detached before removing the bulb. The ma-
jority of these types of bulbs can be removed
from their respective socket by turning them
counterclockwise.

Bulbs
C are used for turn signal and
tail / brake lights and can be removed from
the socket by pushing and turning the bulb
counterclockwise.
CHECKING THE CONDITION OF THE
BULBS
The following procedure applies to all of the
bulbs.
1. Remove:

bulb

Since the headlight bulb gets extremely
hot, keep flammable products and your
hands away from the bulb until it has
cooled down.

When changing the tail / brake light bulb,
confirm that the frame has cooled accord-
ing to the warning label and change the
tail / brake light bulb.
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8-6
CHECKING THE BULBS AND BULB SOCKETSELEC
CAUTION:
NOTE:

Be sure to hold the socket firmly when re-
moving the bulb. Never pull the lead, other-
wise it may be pulled out of the terminal in
the coupler.

Avoid touching the glass part of the head-
light bulb to keep it free from oil, otherwise
the transparency of the glass, the life of the
bulb, and the luminous flux will be adverse-
ly affected. If the headlight bulb gets soiled,
thoroughly clean it with a cloth moistened
with alcohol or lacquer thinner.
2. Check:

bulb (for continuity)
(with the pocket tester)
No continuity
Replace.
Pocket tester
90890-03112, YU-3112
Before checking for continuity, set the pocket
tester to “0” and to the “Ω
1” range.
a. Connect the positive tester probe to terminal
1 and the negative tester probe to terminal
2, and check the continuity.
b. Connect the positive tester probe to terminal
1 and the negative tester probe to terminal
3, and check the continuity.
c. If either of the readings indicate no continuity,
replace the bulb.
CHECKING THE CONDITION OF THE BULB
SOCKETS
The following procedure applies to all of the bulb
sockets.
1. Check:

bulb socket (for continuity)
(with the pocket tester)
No continuity
Replace.
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8-31
High beam indicator light (LEDs)
Positive tester probe
black / yellow
Negative tester probe

black / white
YESNO 1. Headlight bulb and socket

Check the headlight bulb and socket for con-
tinuity.
Refer to “CHECKING THE BULBS AND
BULB SOCKETS”.

Are the headlight bulb and socket OK?
Replace the head-
light bulb, socket or
both.
YESNO 2. Voltage

Connect the pocket tester (DC 20 V) to the
headlight and meter assembly couplers as
shown.
The wiring circuit
from the main switch
to the headlight cou-
pler is faulty and
must be repaired.
When the dimmer switch is set to “ ”
When the dimmer switch is set to “ ”
Headlight coupler (wire harness side)
Low beam
Headlight
Positive tester probe
black
Negative tester probe
black / green
1
2
Meter assembly coupler (wire harness side)

Turn the main switch to “ON”.

Start the engine.

Set the dimmer switch to “ ” or “ ”.

Measure the voltage (DC 12 V) of
black / green or black / yellow on the
headlight coupler (wire harness side).

Is the voltage within specification?
2
This circuit is OK.
A
B
Headlight
Positive tester probe
black
Negative tester probe
black / yellow
A
Headlight coupler (wire harness side)
High beam
B
6
5
3
4
4
LIGHTING SYSTEMELEC
EAS00788
CHECKING THE LIGHTING SYSTEM
1. The headlight and the high beam indicator
light fail to come on.
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9-6
FAULTY LIGHTING OR SIGNALING SYSTEM
TRBL
SHTG
TURN SIGNAL DOES NOT COME ON

Faulty turn signal switch

Faulty turn signal relay

Burnt-out turn signal bulb

Incorrect connection

Damaged or faulty wire harness

Improperly grounded circuit

Faulty battery

Blown, damaged or incorrect fuse
TURN SIGNAL BLINKS SLOWLY

Faulty turn signal relay

Faulty main switch

Faulty turn signal switch

Incorrect turn signal bulb
TURN SIGNAL REMAINS LIT

Faulty turn signal relay

Burnt-out turn signal bulb
TURN SIGNAL BLINKS QUICKLY

Incorrect turn signal bulb

Faulty turn signal relay

Burnt-out turn signal bulb
HORN DOES NOT SOUND

Improperly adjusted horn

Damaged or faulty horn

Faulty main switch

Faulty horn switch

Faulty battery

Blown, damaged or incorrect fuse

Faulty wire harness
EAS00866
FAULTY LIGHTING OR SIGNALING SYSTEM
HEADLIGHT DOES NOT COME ON

Wrong headlight bulb

Too many electrical accessories

Hard charging

Incorrect connection

Improperly grounded circuit

Poor contacts (main or light switch)

Burnt-out headlight bulb
HEADLIGHT BULB BURNT OUT

Wrong headlight bulb

Faulty battery

Faulty rectifier / regulator

Improperly grounded circuit

Faulty main switch

Faulty light switch

Headlight bulb life expired
TAIL / BRAKE LIGHT DOES NOT COME ON

Too many electrical accessories

Incorrect connection
TAIL / BRAKE LIGHT BULB BURNT OUT

Faulty battery

Incorrectly adjusted rear brake light switch
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