2004 YAMAHA YZF-R1S spark plugs
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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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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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2-19
TIGHTENING TORQUESSPEC
Use a lock
washer
TIGHTENING TORQUES
ENGINE TIGHTENING TORQUES
ItemFastenerThreadQ’tyTightening torqueRemarksItemFastenersizeQtyNmmkgftlbRemarks
Spark plugs—M104131.39.4
Cylinder headNutM1010See NOTE 1
BoltM62121.28.7
Camshaft capsBoltM628101.07.2
Cylinder head coverBoltM66121.28.7
Cylinder head (exhaust pipe)Stud boltM88151.511
Air indication system capBoltM64101.07.2
Camshaft sprocketsBoltM74242.417
Cylinder head and throttle bodyClampM5430.32.2
Connecting rod capsBoltM8820+1502.0+15014+150
Generator rotorBoltM101606.043
Timing chain tensionerBoltM62101.07.2
Water pump outlet pipeBoltM61101.07.2
Water pump inlet pipeBoltM61101.07.2
(water pump side)
Water pump inlet pipe (front side)BoltM61101.07.2
Oil / water pump assembly
sprocketBoltM61151.511
Water pumpBoltM62121.28.7
Thermostat coverNutM62101.07.2
Thermostat inlet pipeBoltM61101.07.2
Oil coolerBoltM201636.346
Engine oil drain boltBoltM141434.331
Oil pipeBoltM62101.07.2
Oil strainerBoltM63101.07.2
Oil delivery pipeBoltM63101.07.2
Oil filter union boltBoltM201707.051
Oil filter—M201171.712
Oil panBoltM614121.28.7
Oil panBoltM61121.28.7
Air filter case coverScrewM5101.70.171.2
Throttle body and throttle body
jointClampM5430.32.2
Throttle body and funnelBoltM564.20.423.0
Throttle cableNutM614.50.453.3
Throttle cable adjusterBoltM614.50.453.3
Stator coilScrewM63141.410
Generator rotor cover and
bearing housingScrewM63101.07.2
Pull lever coverBoltM62101.07.2
Thermostat assembly stayBoltM62101.07.2
Starter clutch idler gearBoltM61101.07.2
Clutch bossNutM201959.569Stake
Clutch springBoltM66101.07.2
Drive sprocketNutM221858.561
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3-1
3
INTRODUCTION / PERIODIC MAINTENANCE CHART FOR THE EMISSION
CONTROL SYSTEM / GENERAL MAINTENANCE AND LUBRICATION CHARTCHK
ADJ
EAS00036
PERIODIC CHECKS AND ADJUSTMENTS
INTRODUCTION
This chapter includes all information necessary to perform recommended checks and adjustments. If
followed, these preventive maintenance procedures will ensure more reliable vehicle operation, a
longer service life and reduce the need for costly overhaul work. This information applies to vehicles
already in service as well as to new vehicles that are being prepared for sale, All service technicians
should be familiar with this entire chapter.
PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM
INITIALODOMETER READINGS
No.ITEMROUTINE600 mi
(1000 km)
or
1 month4000 mi
(7000 km)
or
6 months8000 mi
(13000 km)
or
12 months12000 mi
(19000 km)
or
18 months16000 mi
(25000 km)
or
24 months20000 mi
(31000 km)
or
30 months
1*Fuel line
(See page 3-33)Check fuel hoses for cracks or damage.
Replace if necessary.
2*Spark plugs
(See page 3-23)Check Condition.
Adjust gap and clean.
Replace every 8000 mi (13000 km) or 12
months.Replace.Replace.
3*Valve clearance
(See page 3-11)Check and adjust valve clearance when en-
gine is cold.Every 26600 mi (42000 km)
4*Crankcase breather
system
(See page 3-34)Check breather hose for cracks or damage.
Replace if necessary.
5*Electronic fuel injection
(See page 3-17, 21)Check and adjust engine idle speed and syn-
chronization.
6*Exhaust system
(See page 3-35)Check for leakage.
Tighten if necessary.
Replace gasket(s) if necessary.
7*Evaporative emission
control system
(For California only)Check control system for damage.
Replace if necessary.
8*Air induction system
(See page 7-46)Check the air cut-off valve, reed valve, and
hose for damage.
Replace any damaged parts if necessary.
GENERAL MAINTENANCE AND LUBRICATION CHART
INITIALODOMETER READINGS
No.ITEMROUTINE600 mi
(1000 km)
or
1 month4000 mi
(7000 km)
or
6 months8000 mi
(13000 km)
or
12 months12000 mi
(19000 km)
or
18 months16000 mi
(25000 km)
or
24 months20000 mi
(31000 km)
or
30 months
1*Air filter element
(See page 3-32)Check condition and damage.Replace if necessary.
2*Clutch
(See page 3-31)Check operation.Adjust or replace cable.
3*Front brake
(See page 3-42, 44, 45)Check operation, fluid level, and for fluid leak-
age.
Replace brake pads if necessary.
4*Rear brake
(See page 3-43, 44, 45)Check operation, fluid level, and for fluid leak-
age.
Replace brake pads if necessary.
5*Brake hosesCheck for cracks or damage.5*Brake hoses(See page 3-46)Replace.Every 4 years
6*Wheels
(See page 4-3)Check runout and for damage.Replace if necessary.
7*Tires
(See page 3-58)Check tread depth and for damage.Replace if necessary.Check air pressure.Correct if necessary.
8*Wheel bearings
(See page 4-3)Check bearings for smooth operation.Replace if necessary.
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Page 88 of 457
3-11
ADJUSTING THE VALVE CLEARANCE
CHK
ADJ
NOTE:
EAS00045
ENGINE
ADJUSTING THE VALVE CLEARANCE
The following procedure applies to all of the
valves.
Valve clearance adjustment should be made
on a cold engine, at room temperature.
When the valve clearance is to be measured or
adjusted, the piston must be at top dead center
(TDC) on the compression stroke.
1. Remove
rider seat
Refer to “SEATS”.
fuel tank
Refer to “FUEL TANK”.
air filter case
Refer to “AIR FILTER CASE”.
bottom cowlings
side cowlings
Refer to “COWLINGS”.
throttle body assembly
Refer to “THROTTLE BODIES” in chapter 7.
air cut-off valve
Refer to “AIR INDUCTION SYSTEM” in
chapter 7.
radiator
radiator fan motor
Refer to “RADIATOR” in chapter 6.
2. Remove
ignition coils
spark plugs
cylinder head cover
cylinder head cover gasket
Refer to “CAMSHAFT” in chapter 5.
3. Remove
pickup rotor cover
1
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3-23
CHECKING THE SPARK PLUGS
CHK
ADJ
CAUTION:
EAS00059
CHECKING THE SPARK PLUGS
The following procedure applies to all of the
spark plugs.
1. Remove:
side cowlings
bottom cowlings
Refer to “COWLINGS”.
2. Remove:
radiator upper bolts
radiator lower bolt
Refer to “RADIATOR” in chapter 6.
3. Remove:
ignition coils
spark plugs
Before removing the spark plugs, blow away
any dirt accumulated in the spark plug wells
with compressed air to prevent it from fal-
ling into the cylinders.
4. Check:
spark plug type
Incorrect Change.
Spark plug type (manufacturer)
CR9EK (NGK)
5. Check:
electrode
1
Damage / wear Replace the spark plug.
insulator
2
Abnormal color Replace the spark plug.
Normal color is medium-to-light tan.
6. Clean:
spark plug
(with a spark plug cleaner or wire brush)
7. Measure:
spark plug gap
a
(with a wire Thickness gauge)
Out of specification Regap.
Spark plug gap
0.6 0.7 mm
(0.0236 0.0276 in)
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3-24
CHECKING THE SPARK PLUGS /
MEASURING THE COMPRESSION PRESSURECHK
ADJ
13 Nm (1.3 mkg, 9.4 ftlb)
NOTE:
NOTE:
CAUTION:
8. Install:
spark plugs
ignition coils
Before installing the spark plug, clean the spark
plug and gasket surface.
9. Install:
radiator upper bolts
radiator lower bolt
Refer to “RADIATOR” in chapter 6.
10. Install:
side cowlings
bottom cowlings
Refer to “COWLINGS”.
EAS00065
MEASURING THE COMPRESSION
PRESSURE
The following procedure applies to all of the cyl-
inders.
Insufficient compression pressure will result in a
loss of performance.
1. Measure:
valve clearance
Out of specification Adjust.
Refer to “ADJUSTING THE VALVE CLEAR-
ANCE”.
2. Start the engine, warm it up for several min-
utes, and then turn it off.
3. Remove:
ignition coils
spark plugs
Before removing the spark plugs, use com-
pressed air to blow away any dirt accumu-
lated in the spark plug wells to prevent it
from falling into the cylinders.
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Page 403 of 457
8-10
YESNO 2. Battery
Check the condition of the battery.
Refer to “CHECKING AND CHARGING
THE BATTERY” in chapter 3.
Minimum open-circuit voltage
12.8 V or more at 20C (68F)
Is the battery OK?
Clean the battery
terminals.
Recharge or re-
place the battery.
EAS00739
YESNO
EAS00741
3. Spark plugs
The following procedure applies to all of the
spark plugs.
Check the condition of the spark plug.
Check the spark plug type.
Measure the spark plug gap.
Refer to “CHECKING THE SPARK PLUGS”
in chapter 3.
Standard spark plug
CR9EK (NGK)
Spark plug gap
0.6 0.7 mm (0.0236 0.0276 in)
Is the spark plug in good condition, is it of the
correct type, and is its gap within specifica-
tion?
Re-gap or replace
the spark plug.
IGNITION SYSTEMELEC
NOTE:
YESNO
1. Main and ignition fuses
Check the main and ignition fuses for conti-
nuity.
Refer to “CHECKING THE FUSES” in chap-
ter 3.
Are the main and ignition fuses OK?
Replace the fuse(s).
EAS00737
TROUBLESHOOTING
The ignition system fails to operate (no
spark or intermittent spark).
Check:
1. main and ignition fuses
2. battery
3. spark plugs
4. ignition spark gap
5. ignition coil resistance
6. crankshaft position sensor
7. main switch
8. engine stop switch
9. neutral switch
10. sidestand switch
11. clutch switch
12. starting circuit cut-off relay (diode)
13. lean angle cut-off switch
14. wiring connections
(of the entire ignition system)
Before troubleshooting, remove the following
part(s):
1. seat
2. fuel tank
3. side cowlings
Troubleshoot with the following special tool(s).
Ignition checker
90890-06754
Dynamic spark tester
YM-34487
Pocket tester
90890-03112, YU-3112
EAS00738
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