2004 YAMAHA YZF-R1S brake

4-57
HANDLEBARSCHAS
Order Job / Part Q’ty Remarks
16
17
18
19
20
21
22
23
24Brake master cylinder
Steering damper
Handlebar pinch bolt
Upper bracket bolt
Upper bracket pinch bolt
Steering stem nut
Upper bracket
Left handlebar
Right handlebar1
1
2
2
2
1
1
1
1
For assembly, reverse the disassembly
procedure.
113 Nm (11.3 m
kg, 82 ft
lb)
17 Nm (1.7 m
kg, 12 ft
lb)
11 Nm (1.1 m
kg, 8.0 ft
lb)
23 Nm (2.3 m
kg, 17 ft
lb)
13 Nm (1.3 m
kg, 9.4 ft
lb)
23 Nm (2.3 m
kg, 17 ft
lb)3.8 Nm (0.38 m
kg, 2.7 ft
lb)
3.8 Nm (0.38 m
kg, 2.7 ft
lb)
3.8 Nm (0.38 m
kg, 2.7 ft
lb)
13 Nm (1.3 m
kg, 9.4 ft
lb)
26 Nm (2.6 m
kg, 19 ft
lb)
17 Nm (1.7 m
kg, 12 ft
lb)
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4-59
HANDLEBARSCHAS
NOTE:
CAUTION:
NOTE:
NOTE:
NOTE: 2. Install:

right handlebar switch
1
Align the projection a on the right handlebar
switch with the hole
b in the right handlebar.
3. Install:

brake master cylinder holder
1

Install the brake master cylinder holder
with the “UP” mark facing up.

First, tighten the upper bolt, then the lower
bolt.

Align the mating surfaces of the brake master
cylinder holder with the punch mark
a in the
right handlebar.

There should be 2 mm (0.08 in) of clearance
between the right handlebar switch and the
brake master cylinder holder.
4. Install:

throttle grip

throttle cable housing
1

throttle cables
Align the projection
a on the throttle cable
housing with the hole
b in the right handlebar.
5. Install:

clutch lever holder
1
Align the slit in the clutch lever holder with the
punch mark
a in the left handlebar.
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4-61
Order Job / Part Q’ty Remarks
1
2
3
4
5
6
7
8
9
10Removing the under bracket
Front wheel
Front cowling and side cowling
Front fork legs
Main switch connector
Upper bracket bolt
Left handlebar assembly
Right handlebar assembly
Steering stem nut
Upper bracket
Under bracket panel
Brake hose holder bolt
Lock washer
Upper ring nut2
2
1
1
1
1
1
1
1
1Remove the parts in the order listed.
Refer to “FRONT WHEEL AND BRAKE
DISCS”.
Refer to “COWLINGS” in chapter 3.
Refer to “FRONT FORK”.
Disconnect.
For installation, reverse the removal
procedure.
38 Nm (0.38 m
kg, 2.75 ft
lb)113 Nm (11.3 m
kg, 82 ft
lb)
52 Nm (5.2 m
kg, 38 ft
lb)
18 Nm (1.8 m
kg, 13 ft
lb)
1st
2nd23 Nm (2.3 m
kg, 17 ft
lb)
23 Nm (2.3 m
kg, 17 ft
lb)
7 Nm (0.7 m
kg, 5.1 ft
lb)
17 Nm (1.7 m
kg, 12 ft
lb)
STEERING HEADCHAS
EAS00676
STEERING HEAD
UNDER BRACKET
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4-69
SWINGARM AND DRIVE CHAINCHAS
Order Job / Part Q’ty Remarks
1
2
3
4
5
6
7Removing the swingarm and drive
chain
Rear wheel
Rear shock absorber
Drive sprocket
Muffler
Catalyst pipe assembly
Right footrest bracket
Adjusting bolt / locknut
Drive chain guard
Rear fender
Brake hose holder
Pivot shaft nut / washer
Pivot shaft1
2/2
1
1
1
1/1
1Remove the parts in the order listed.
Refer to “REAR WHEEL AND BRAKE
DISC”.
Refer to “REAR SHOCK ABSORBER
ASSEMBLY”.
Refer to “ENGINE REMOVAL” in chapter
5.
Refer to “EXHAUST PIPE” in chapter 5.
Refer to “EXHAUST PIPE” in chapter 5.
28 Nm (2.8 m
kg, 20 ft
lb)
7 Nm (0.7 m
kg, 5.1 ft
lb)
7 Nm (0.7 m
kg, 5.1 ft
lb)
105 Nm (10.5 m
kg, 76 ft
lb)
2 Nm (0.2 m
kg, 1.4 ft
lb)
16 Nm (1.6 m
kg, 12 ft
lb)
EAS00700
SWINGARM AND DRIVE CHAIN
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8-1
8
ELECTRICAL COMPONENTSELEC
9Oil level switch
10Radiator fan motor
11Horn
12Ignition coil
1Main switch
2Front brake light switch
3Starter relay
4Battery
5Fuse box
6Rear brake light switch
7Neutral switch
8Sidestand switch
EAS00729
ELECTRICAL SYSTEM
ELECTRICAL COMPONENTS
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8-4
11Neutral switch
12Rear brake light switch
13Fuse box
1Main switch
2Horn switch
3Dimmer switch
4Turn signal switch
5Clutch switch
6Sidestand switch
7Engine stop switch
8Front brake light switch
9Start switch
10Oil level switch
CHECKING THE SWITCHESELEC
EAS00731
CHECKING THE SWITCHES
Check each switch for damage or wear, proper connections, and also for continuity between the termi-
nals. Refer to “CHECKING SWITCH CONTINUITY”.
Damage / wear
Repair or replace.
Improperly connected
Properly connect.
Incorrect continuity reading
Replace the switch.
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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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8-28
LIGHTING SYSTEMELEC
1Main switch
4Fuse (main)
6Battery
14E.C.U.
46Hi beam indicator light
49Meter light
57Dimmer switch
62Front turn signal/position light (left)
63Front turn signal/position light (right)
66Headlight
67Auxiliary light
68License plate light
69Rear brake light switch
70Tail/brake light
71Headlight relay (on / off)
72Headlight relay (dimmer)
74Fuse (signal)
75Fuse (headlight)
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