2004 YAMAHA YZF-R1S Service Manual

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EAS00010
YZF-R1S / YZF-R1SC
SERVICE MANUAL
2003 by Yamaha Motor
Corporation, U.S.A.
First edition, December 2003
All rights reserved. Any reproduction
or unauthorized use without the written
permission of Yamaha Motor Corporation,
U.S.A. is expressly prohibited.
Printed in U.S.A.
P / N LIT-11616-17-55
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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.
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4
8
3
5
6
7
EAS00007
HOW TO USE THIS MANUAL
This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive
explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid
out with the individual steps in sequential order.
1 The manual is divided into chapters. An abbreviation and symbol in the upper right corner of each
page indicate the current chapter.
Refer to “SYMBOLS”.
2 Each chapter is divided into sections. The current section title is shown at the top of each page,
except in Chapter 3 (“PERIODIC CHECKS AND ADJUSTMENTS”), where the sub-section title(s) ap-
pears.
3 Sub-section titles appear in smaller print than the section title.
4 To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each
removal and disassembly section.
5 Numbers are given in the order of the jobs in the exploded diagram. A circled number indicates a
disassembly step.
6 Symbols indicate parts to be lubricated or replaced.
Refer to “SYMBOLS”.
7 A job instruction chart accompanies the exploded diagram, providing the order of jobs, names of
parts, notes in jobs, etc.
8 Jobs requiring more information (such as special tools and technical data) are described sequen-
tially.
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1
3
5
7
9
2
4
8
6
2425
2321
192018
161715
1413
1112
10
GEN
INFOSPEC
ENG
FI ELECCOOL CHK
ADJ
TRBL
SHTG
CHAS
EAS00008
SYMBOLS
The following symbols are not relevant to every
vehicle.
Symbols
1 to 9 indicate the subject of each
chapter.
1General information
2Specifications
3Periodic checks and adjustments
4Chassis
5Engine
6Cooling system
7Fuel injection system
8Electrical system
9Troubleshooting
Symbols 10 to 17 indicate the following.
10Serviceable with engine mounted
11Filling fluid
12Lubricant
13Special tool
14Tightening torque
15Wear limit, clearance
16Engine speed
17Electrical data
Symbols 18 to 23 in the exploded diagrams indi-
cate the types of lubricants and lubrication
points.
18Engine oil
19Gear oil
20Molybdenum-disulfide oil
21Wheel-bearing grease
22Lithium-soap- based grease
23Molybdenum-disulfide grease
Symbols 24 to 25 in the exploded diagrams indi-
cate the following.
24Apply locking agent (LOCTITE)
25Replace the part
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GENERAL INFORMATION
SPECIFICATIONS
PERIODIC CHECKS AND
ADJUSTMENTS
CHASSIS
ENGINE
COOLING SYSTEM
FUEL INJECTION SYSTEM
ELECTRICAL SYSTEM
TROUBLESHOOTING
GEN
INFO
1
SPEC2
3
ENG
4
COOL
5
FI
6
CHAS
7
ELEC8
TRBL
SHTG
9
CHK
ADJ
EAS00012
TABLE OF CONTENTS
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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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