warning YAMAHA YZF-R1S 2004 Service Manual
[x] Cancel search | Manufacturer: YAMAHA, Model Year: 2004, Model line: YZF-R1S, Model: YAMAHA YZF-R1S 2004Pages: 457, PDF Size: 7.58 MB
Page 3 of 457
NOTE:
WARNING
CAUTION:
EAS00030
NOTICE
This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha dealers
and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manu-
al. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles
should have a basic understanding of mechanics and the techniques to repair these types of vehicles.
Repair and maintenance work attempted by anyone without this knowledge is likely to render the ve-
hicle unsafe and unfit for use.
This model has been designed and manufactured to perform within certain specifications in regard to
performance and emissions. Proper service with the correct tools is necessary to ensure that the ve-
hicle will operate as designed. If there is any question about a service procedure, it is imperative that
you contact a Yamaha dealer for any service information changes that apply to this model. This policy
is intended to provide the customer with the most satisfaction from his vehicle and to conform to federal
environmental quality objectives.
Yamaha Motor Company, Ltd. is continually striving to improve all of its models. Modifications and sig-
nificant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers
and will appear in future editions of this manual where applicable.
This Service Manual contains information regarding periodic maintenance to the emission control
system. Please read this material carefully.
Designs and specifications are subject to change without notice.
EAS00040
IMPORTANT MANUAL INFORMATION
Particularly important information is distinguished in this manual by the following.
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR
SAFETY IS INVOLVED!
Failure to follow WARNING instructions could result in severe injury or death
to
the motorcycle operator, a bystander or a person checking or repairing the mo-
torcycle.
A CAUTION indicates special precautions that must be taken to avoid damage
to the motorcycle.
NOTE:A NOTE provides key information to make procedures easier or clearer.
ProCarManuals.com
Page 18 of 457
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.
ProCarManuals.com
Page 19 of 457
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.
ProCarManuals.com
Page 20 of 457
1-4
FEATURES
GEN
INFO
NOTE: Self-diagnosis devices
The model is equipped with a self-diagnosis device for various electrical circuits. If any of those circuits
are defective, the engine trouble warning light will come on, and then the right display will indicate a
two-digit error code (e.g.,11,12,13).
Display brightness and shift timing indicator light control mode
This mode cycles through five control functions, allowing you to make the following settings in the order
listed below.
Display brightness:
This function allows you to adjust the brightness of the displays and tachometer to suit the outside
lighting conditions.
Shift timing indicator light activity:
This function allows you to choose whether or not the indicator light should be activated and whether
it should flash or stay on when activated.
Shift timing indicator light activation:
This function allows you to select the engine speed at which the indicator light will be activated.
Shift timing indicator light deactivation:
This function allows you to select the engine speed at which the indicator light will be deactivated.
Shift timing indicator light brightness:
This function allows you to adjust the brightness of the indicator light to suit your preference.
To make any settings in this mode, you have to cycle through all of its functions. However, if the key is
turned to “OFF” or the engine is started before completing the procedure, only the settings made be-
fore the “SELECT” button was last pushed will be applied.
In this mode, the right display shows the current setting for each function (except the shift timing indi-
cator light activity function).
To adjust the brightness of the multifunction meter displays and tachometer
1. Turn the key to “OFF”.
2. Push and hold the “SELECT” button.
3. Turn the key to “ON”, and then release the “SELECT” button after five seconds.
4. Push the “RESET” button to select the desired brightness level.
5. Push the “SELECT” button to confirm the selected brightness level. The control mode changes to
the shift timing indicator light activity function.
To set the shift timing indicator light activity function
1. Push the “RESET” button to select one of the following indicator light activity settings:
The indicator light will stay on when activated. (This setting is selected when the indicator light stays
on.)
The indicator light will flash when activated. (This setting is selected when the indicator light flashes
four times per second.)
The indicator light is deactivated; in other words, it will not come on or flash. (This setting is selected
when the indicator light flashes once every two seconds.)
2. Push the ”SELECT” button to confirm the selected indicator light activity. The control mode changes
to the shift timing indicator light activation function.
ProCarManuals.com
Page 44 of 457
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)
ProCarManuals.com
Page 99 of 457
3-22
ADJUSTING THE THROTTLE CABLE FREE PLAY
CHK
ADJ
NOTE:
a
b
WARNING
EAS00056
ADJUSTING THE THROTTLE CABLE FREE
PLAY
Prior to adjusting the throttle cable free play, the
engine idling speed should be adjusted proper-
ly.
1. Check:
throttle cable free play
a
Out of specification Adjust.
Throttle cable free play (at the
flange of the throttle grip)
3 5 mm (0.12 0.20 in)
2. Adjust:
throttle cable free play
Handlebar side
a. Loosen the locknut
1.
b. Turn the adjusting nut
2 in direction a or b
until the specified throttle cable free play is
obtained.
Direction
Throttle cable free play is
increased.
DirectionThrottle cable free play is
decreased.
c. Tighten the locknut.
After adjusting the throttle cable free play,
start the engine and turn the handlebars to
the right and to the left to ensure that this
does not cause the engine idling speed to
change.
ProCarManuals.com
Page 102 of 457
3-25
MEASURING THE COMPRESSION PRESSURE
CHK
ADJ
WARNING
NOTE: 4. Install:
compression gauge
1
adapter
Compression gauge
90890-03081, YU-33223
Adapter
90890-04136
5. Measure:
compression pressure
Out of specification Refer to steps (c) and
(d).
Compression pressure
(at sea level)
Minimum
1,290 kPa (12.90 kg / cm
2,
12.90 bar, 183.48 psi)
Standard
1,480 kPa (14.80 kg / cm
2,
14.80 bar, 210.5 psi)
Maximum
1,660 kPa (16.60 kg / cm
2,
16.60 bar, 236.11 psi)
a. Turn the main switch to “ON”.
b. With the throttle wide open, crank the engine
until the reading on the compression gauge
stabilizes.
To prevent sparking, ground all spark plug
leads before cranking the engine.
The difference in compression pressure be-
tween cylinders should not exceed 100 kPa (1
kg/cm
2, 1 bar, 14.22 psi).
c. If the compression pressure is above the
maximum specification, check the cylinder
head, valve surfaces and piston crown for
carbon deposits.
Carbon deposits Eliminate.
ProCarManuals.com
Page 107 of 457
3-30
MEASURING THE ENGINE OIL PRESSURE
CHK
ADJ
WARNING
NOTE: 4. Remove:
oil gallery bolt
1
The engine, muffler and engine oil are ex-
tremely hot.
5. Install:
oil pressure gauge
1
adapter 2
Pressure gauge
90890-03153, YU-03153
Oil pressure adapter
90890-03139
6. Measure:
engine oil pressure
(at the following conditions)
Engine oil pressure
230 kPa
(2.3 kg / cm
2, 2.3 bar, 32.71 psi)
Engine speed
Approx. 5,000 r / min
Engine oil temperature
100C (212F)
Regarding the oil pressure as its own data may
fluctuate depending on the oil temperature and
viscosity, the oil pressure may fluctuate when
measuring. The following data should be used
only as a reference when measuring the engine
oil pressure.
ProCarManuals.com
Page 112 of 457
3-35
CHECKING THE EXHAUST SYSTEM
CHK
ADJ
WARNING
NOTE:
EAS00099
CHECKING THE EXHAUST SYSTEM
The following procedure applies to all of the ex-
haust pipes and gaskets.
Do not touch the muffler bracket until the ex-
haust system has cooled.
1. Check:
exhaust pipe
1
exhaust valve pipe 2
muffler 3
Cracks / damage Replace.
gaskets
4
Exhaust gas leaks Replace.
2. Check:
tightening torque
Exhaust pipe nut
5
20 Nm (2.0 mkg, 14 ftlb)
Exhaust pipe and exhaust valve
pipe bolt
6
10 Nm (1.0 mkg, 7.2 ftlb)
Catalyst pipe assembly bolt
7
20 Nm (2.0mkg, 14 ftlb)
Catalyst pipe assembly and
muffler bolt
8
20 Nm (2.0 mkg, 14 ftlb)
Muffler cover
9
10 Nm (1.0 mkg, 7.2 ftlb)
Install the EXUP cable in parallel without twist-
ing its upper
10 and lower sides 11.
black metal
10 is upper.
white metal
11 is lower.
ProCarManuals.com
Page 117 of 457
3-40
CHANGING THE COOLANT
CHK
ADJ
10 Nm (1.0 mkg, 7.2 ftlb)
WARNING
7. Drain:
coolant
(water pump inlet pipe and outlet pipe)
8. Check:
copper washers
1 New
9. Install:
coolant drain bolts
2
(with copper washers)
10. Install:
coolant reservoir tank
11. Connect:
coolant reservoir hose
12. Fill:
cooling system
(with the specified amount of the recom-
mended coolant)
Recommended antifreeze
High-quality ethylene glycol
antifreeze containing corrosion
inhibitors for aluminum engines
Mixing ratio
1:1 (antifreeze:water)
Quantity
Total amount
2.51 L
(2.21 Imp qt, 2.65 US qt)
Coolant reservoir capacity
0.25 L
(0.22 Imp qt, 0.26 US qt)
Handling notes for coolant
Coolant is potentially harmful and should be
handled with special care.
If coolant splashes in your eyes, thorough-
ly wash them with water and consult a doc-
tor.
If coolant splashes on your clothes, quick-
ly wash it away with water and then with
soap and water.
If coolant is swallowed, induce vomiting
and get immediate medical attention.
ProCarManuals.com