width YAMAHA YZF-R1S 2004 Service Manual

2-1
GENERAL SPECIFICATIONSSPEC
SPECIFICATIONS
GENERAL SPECIFICATIONS
ItemStandardLimit
Model code5VY4 (USA), 5VY5 (CAL)



Dimensions
Overall length
Overall width
Overall height
Seat height
Wheelbase
Minimum ground clearance
Minimum turning radius
2,065 mm (8.13 in)
720 mm (28.3 in)
1,105 mm (43.5 in)
835 mm (32.9 in)
1,395 mm (54.9 in)
135 mm (5.31 in)
3,400 mm (133.9 in)



























Weight
Wet (with oil and a full fuel tank)
Maximum load (except motorcycle)
193 kg (425 lb) (USA)
194 kg (428 lb) (CAL)
202 kg (445 lb) (USA)
201 kg (443 lb) (CAL)







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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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2-5
ENGINE SPECIFICATIONSSPEC
Head Diameter Face Width Seat Width Margin Thickness
ItemStandardLimit
Timing chain
Model / number of links
Tensioning system
RH2020 / 122
Automatic







Valves, valve seats, valve guides
Valve clearance (cold)
Intake
Exhaust
Valve dimensions
0.11  0.20 mm (0.0043  0.0079 in)
0.21  0.25 mm (0.0083  0.0098 in)







Valve head diameter A
Intake
Exhaust
Valve face width B
Intake
Exhaust
Valve seat width C
Intake
Exhaust
Valve margin thickness D
Intake
Exhaust
Valve stem diameter
Intake
Exhaust
Valve guide inside diameter
Intake
Exhaust
Valve-stem-to-valve-guide clearance
Intake
Exhaust
Valve stem runout
Valve seat width
Intake
Exhaust
23.4  23.6 mm (0.9213  0.9291 in)
24.9  25.1 mm (0.9803  0.9882 in)
1.76  2.90 mm (0.0693  0.1142 in)
1.76  2.90 mm (0.0693  0.1142 in)
0.9  1.1 mm (0.0354  0.0433 in)
0.9  1.1 mm (0.0354  0.0433 in)
0.5  0.9 mm (0.0197  0.0354 in)
0.5  0.9 mm (0.0197  0.0354 in)
3.975  3.990 mm (0.1565  0.1571 in)
4.460  4.475 mm (0.1756  0.1762 in)
4.000  4.012 mm (0.1575  0.1580 in)
4.500  4.512 mm (0.1772  0.1776 in)
0.010  0.037 mm (0.0004  0.0015 in)
0.025  0.052 mm (0.0010  0.0020 in)




0.9  1.1 mm (0.0354  0.0433 in)
0.9  1.1 mm (0.0354  0.0433 in)















1.6 mm (0.06 in)
1.6 mm (0.06 in)
0.5 mm (0.02 in)
0.5 mm (0.02 in)
3.945 mm
(0.1553 in)
4.425 mm
(0.1742 in)
4.050 mm
(0.1594 in)
4.550 mm
(0.1791 in)
0.08 mm
(0.0032 in)
0.10 mm
(0.0039 in)
0.01 mm
(0.0004 in)
1.6 mm (0.06 in)
1.6 mm (0.06 in)
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2-8
ENGINE SPECIFICATIONSSPEC
ItemStandardLimit
Connecting rods
Crankshaft-pin-to-big-end-bearing
clearance
Bearing color code
0.034  0.058 mm (0.0013  0.0023 in)
1 = Blue 2 = Black 3 = Brown 4 = Green0.09 mm
(0.0035 in)




Crankshaft
Width A
Width B
Max. runout C
Big end side clearance D
Crankshaft-journal-to-crankshaft-
journal-bearing clearance
Bearing color code
55.20  56.60 mm (2.17  2.23 in)
298.8  300.7 mm (11.76  11.84 in)




0.160  0.262 mm (0.0063  0.0103 in)
0.014  0.037 mm (0.0006  0.0015 in)
0 = White 1 = Blue 2 = Black
3 = Brown 4 = Green







0.03 mm
(0.0012 in)




0.10 mm
(0.0039 in)




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5-16
CAMSHAFTENG
NOTE:
3. Measure:

camshaft runout
Out of specification
Replace.
Camshaft runout limit
0.03 mm (0.0012 in)
4. Measure:

camshaft-journal-to-camshaft-cap clear-
ance
Out of specification
Measure the camshaft
journal diameter.
Camshaft-journal-to-camshaft-
cap clearance
0.028
0.062 mm
(0.0011
0.0024 in)
a. Install the camshaft into the cylinder head
(without the dowel pins and camshaft caps).
b. Position strip of Plastigauge
 1 onto the
camshaft journal as shown.
c. Install the dowel pins and camshaft caps.

Tighten the camshaft cap bolts in stages and in
a crisscross pattern, working from the inner
caps out.

Do not turn the camshaft when measuring the
camshaft journal-to-camshaft cap clearance
with the Plastigauge
.
Camshaft cap bolt
10 Nm (1.0 m
kg, 7.2 ft
lb)
d. Remove the camshaft caps and then mea-
sure the width of the Plastigauge
 1.
5. Measure:

camshaft journal diameter
a
Out of specification
Replace the cam-
shaft.
Within specification
Replace the cylinder
head and the camshaft caps as a set.
Camshaft journal diameter
22.459
22.472 mm
(0.8842
0.8847 in)
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5-27
VALVES AND VALVE SPRINGSENG
NOTE:
NOTE:
NOTE:
NOTE:
EAS00237
REMOVING THE VALVES
The following procedure applies to all of the
valves and related components.
Before removing the internal parts of the cylin-
der head (e.g., valves, valve springs, valve
seats), make sure the valves properly seal.
1. Remove:

valve lifter
1

valve pad 2
Make a note of the position of each valve lifter
and valve pad so that they can be reinstalled in
their original place.
2. Check:

valve sealing
Leakage at the valve seat
Check the valve
face, valve seat, and valve seat width.
Refer to “CHECKING THE VALVE SEATS”.
a. Pour a clean solvent
a into the intake and
exhaust ports.
b. Check that the valves properly seal.
There should be no leakage at the valve seat
1.
3. Remove:

valve cotters
1
Remove the valve cotters by compressing the
valve spring with the valve spring compressor
2 and the valve spring compressor attachment
3.
Valve spring compressor
90890-04019, YM-04019
Valve spring compressor
attachment
Intake valve
90890-04114, YM-4114
Exhaust valve
90890-04108, YM-4108
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5-30
VALVES AND VALVE SPRINGSENG
NOTE:
NOTE:
EAS00240
CHECKING THE VALVE SEATS
The following procedure applies to all of the
valves and valve seats.
1. Eliminate:

carbon deposits
(from the valve face and valve seat)
2. Check:

valve seat
Pitting / wear
Replace the cylinder head.
3. Measure:

valve seat width
a
Out of specification
Replace the cylinder
head.
Valve seat width
Intake: 0.9
1.1 mm
Intake: (0.0354
0.0433 in)
Exhaust: 0.9
1.1 mm
Exhaust: (0.0354
0.0433 in)
: 1.6 mm (0.06 in)
a. Apply Mechanic’s blueing dye (Dykem)
1
onto the valve face.
b. Install the valve into the cylinder head.
c. Press the valve through the valve guide and
onto the valve seat to make a clear impres-
sion.
d. Measure the valve seat width.
Where the valve seat and valve face contacted
one another, the blueing will have been re-
moved.
4. Lap:

valve face

valve seat
After replacing the cylinder head or replacing
the valve and valve guide, the valve seat and
valve face should be lapped.
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5-31
VALVES AND VALVE SPRINGSENG
CAUTION:
NOTE:
a. Apply a coarse lapping compound a to the
valve face.
Do not let the lapping compound enter the
gap between the valve stem and the valve
guide.
b. Apply molybdenum disulfide oil onto the
valve stem.
c. Install the valve into the cylinder head.
d. Turn the valve until the valve face and valve
seat are evenly polished, then clean off all of
the lapping compound.
For the best lapping results, lightly tap the valve
seat while rotating the valve back and forth be-
tween your hands.
e. Apply a fine lapping compound to the valve
face and repeat the above steps.
f. After every lapping procedure, be sure to
clean off all of the lapping compound from
the valve face and valve seat.
g. Apply Mechanic’s blueing dye (Dykem) onto
the valve face.
h. Install the valve into the cylinder head.
i. Press the valve through the valve guide and
onto the valve seat to make a clear impres-
sion.
j. Measure the valve seat width
a again. If the
valve seat width is out of specification, reface
and lap the valve seat.
EAS00241
CHECKING THE VALVE SPRINGS
The following procedure applies to all of the
valve springs.
1. Measure:

valve spring free length
a
Out of specification
Replace the valve
spring.
Valve spring free length
Intake valve spring
39.3 mm (1.55 in)
: 37.3 mm (1.47 in)
Exhaust valve spring
39.3 mm (1.55 in)
: 37.3 mm (1.47 in)
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5-86
CONNECTING RODS AND PISTONSENG
NOTE:
r. Measure the compressed Plastigauge
width on the crankshaft pin.
If the crankshaft-pin-to-big-end-bearing
clearance is out of specification, select re-
placement big end bearings.
2. Select:

big end bearings (P1
P4)

The numbers
A stamped into the crankshaft
web and the numbers
1 on the connecting
rods are used to determine the replacement
big end bearing sizes.

“P1”
“P4” refer to the bearings shown in the
crankshaft illustration.
For example, if the connecting rod “P
1” and the
crankshaft web “P
1” numbers are “5” and “2” re-
spectively, then the bearing size for “P1” is:
“P
1” (connecting rod) – “P1”
(crankshaft) =
5 – 2 = 3 (brown)
BIG END BEARING COLOR CODE
1Blue
2Black
3Brown
4Green
INSTALLING THE CONNECTING ROD AND
PISTON
The following procedure applies to all of the
connecting rods and pistons.
1. Install:

top ring
1

2nd ring 2

upper oil ring rail 3

oil ring expander 4

lower oil ring rail 5
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5-95
CRANKSHAFTENG
NOTE:
NOTE:
* Following the tightening order, loosen the bolt
one by one and then retighten it to the specific
torque.
Lubricate the crankcase bolt threads with en-
gine oil.
Refer to “CRANKCASE”.
g. Remove the lower crankcase and the crank-
shaft journal lower bearings.
h. Measure the compressed Plastigauge

width c on each crankshaft journal.
If the crankshaft-journal-to-crankshaft-jour-
nal-bearing clearance is out of specification,
select replacement crankshaft journal bear-
ings.
2. Select:

crankshaft journal bearings (J1
J5)

The numbers
A stamped into the crankshaft
web and the numbers
1 stamped into the low-
er crankcase are used to determine the re-
placement crankshaft journal bearing sizes.

“J1
J5” refer to the bearings shown in the
crankshaft illustration.

If “J1
J5” are the same, use the same size
for all of the bearings.

If the size is the same for all “J
1 to J5” one digit
for that size is indicated. (Crankcase side only)
For example, if the crankcase “J
1” and crank-
shaft web “J
1” numbers are “6” and “2” respec-
tively, then the bearing size for “J1” is:
“J
1” (crankcase) – “J1”
(crankshaft web) – 1 =
6 – 2 – 1 = 3 (brown)
CRANKSHAFT JOURNAL BEARING
COLOR CODE
0White
1Blue
2Black
3Brown
4Green
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