2004 YAMAHA YZF-R1S Service Manual

3-12
ADJUSTING THE VALVE CLEARANCE
CHK
ADJ
NOTE:
NOTE:
4. Measure:

valve clearance
Out of specification
Adjust.
Valve clearance (cold)
Intake valve
0.11  0.20 mm
(0.0043  0.0079 in)
Exhaust valve
0.21  0.25 mm
(0.0083  0.0098 in)
a. Turn the crankshaft counterclockwise.
b. When piston #1 is at TDC on the compres-
sion stroke, align the TDC mark
a on the
pickup rotor with the crankcase mating sur-
face
b.
TDC on the compression stroke can be found
when the camshaft lobes are turned away from
each other.
c. Measure the valve clearance with a thick-
ness gauge
1.

If the valve clearance is incorrect, record the
measured reading.

Measure the valve clearance in the following
sequence.
Valve clearance measuring sequence
Cylinder #1
#2
#4
#3
AFront
d. To measure the valve clearances of the other
cylinders, starting with cylinder #1 at TDC,
turn the crankshaft counterclockwise as spe-
cified in the following table.
BDegrees that the crankshaft is turned counter-
clockwise
CCylinder
DCombustion cycle
Cylinder #2180
Cylinder #4360
Cylinder #3540
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3-13
ADJUSTING THE VALVE CLEARANCE
CHK
ADJ
NOTE:
NOTE:
NOTE: 5. Remove:

camshafts

Refer to “DISASSEMBLING THE ENGINE –
CAMSHAFT AND CYLINDER HEAD” in chap-
ter 5.

When removing the timing chain and cam-
shafts, fasten the timing chain with a wire to re-
trieve it if it falls into the crankcase.
6. Adjust:

valve clearance
a. Remove the valve lifter
1 and the valve pad
2 with a valve lapper 3.
Valve lapper
90890-04101

Cover the timing chain opening with a rag to
prevent the valve pad from falling into the
crankcase.

Make a note of the position of each valve lifter
2 and valve pad 1 so that they can be
installed in the correct place.
b. Select the proper valve pad from the follow-
ing table.
Valve pad
thickness range
Available valve
pads
Nos.
120 
2401.20
(0.0472) 
2.40 mm
(0.0945 in)25 thicknesses in
0.05 mm (0.002 in)
increments

The thickness a of each valve pad is marked
in hundredths of millimeters on the side that
touches the valve lifter.

Since valve pads of various sizes are originally
installed, the valve pad number must be
rounded in order to reach the closest equiva-
lent to the original.
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3-14
ADJUSTING THE VALVE CLEARANCE
CHK
ADJ
NOTE:
NOTE:
c. Round off the original valve pad number ac-
cording to the following table.
Last digit
Rounded value
0 or 20
55
810
EXAMPLE:
Original valve pad number
= 148 (thickness =1.48 mm (0.058 in))
Rounded value = 150
d. Locate the rounded number of the original
valve pad and the measured valve clearance
in the valve pad selection table. The point
where the column and row intersect is the
new valve pad number.
The new valve pad number is only an approxi-
mation. The valve clearance must be measured
again and the above steps should be repeated if
the measurement is still incorrect.
e. Install the new valve pad
1 and the valve lift-
er
2.

Lubricate the valve pad with molybdenum dis-
ulfide grease.

Lubricate the valve lifter with molybdenum dis-
ulfide oil.

The valve lifter must turn smoothly when ro-
tated by hand.

Install the valve lifter and the valve pad in the
correct place.
f. Install the exhaust and intake camshafts,
timing chain and camshaft caps.
Camshaft cap bolt
10 Nm (1.0 m
kg, 7.2 ft
lb)
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3-15
ADJUSTING THE VALVE CLEARANCE
CHK
ADJ
NOTE:

Refer to “ASSEMBLING AND ADJUSTING
THE ENGINE – CYLINDER HEAD AND CAM-
SHAFT” in chapter 5.

Lubricate the camshaft bearings, camshaft
lobes and camshaft journals.

First, install the exhaust camshaft.

Align the camshaft marks with the camshaft
cap marks.

Turn the crankshaft counterclockwise several
full turns to seat the parts.
g. Measure the valve clearance again.
h. If the valve clearance is still out of specifica-
tion, repeat all of the valve clearance adjust-
ment steps until the specified clearance is
obtained.
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3-16
ADJUSTING THE VALVE CLEARANCE
CHK
ADJ
VALVE CLEARANCE (cold):
0.11  0.20 mm (0.0043  0.0079 in)
Example: Installed is 175
Measured clearance is 0.27 mm (0.0106 in)
Replace 175 pad with 185 pad
Pad number: (example)
Pad No.175 = 1.75 mm (0.0689 in)
Pad No.185 = 1.85 mm (0.0728 in)
MEASURED
CLEARANCEINSTALLED PAD NUMBER
VALVE CLEARANCE (cold):
0.21  0.25 mm (0.0083  0.0098 in)
Example: Installed is 175
Measured clearance is 0.35 mm (0.0138 in)
Replace 175 pad with 185 pad
Pad number: (example)
Pad No.175 = 1.75 mm (0.0689 in)
Pad No.185 = 1.85 mm (0.0728 in)
MEASURED
CLEARANCEINSTALLED PAD NUMBER
STANDARD CLEARANCE
STANDARD CLEARANCE
INTAKE
120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.00  0.02 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225
0.03  0.07 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230
0.08  0.10 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235
0.11  0.20
0.21  0.25 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.26  0.30 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.31  0.35 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.36  0.40 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.41  0.45 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.46  0.50 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.51  0.55 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.56  0.60 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.61  0.65 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.66  0.70 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.71  0.75 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.76  0.80 180 185 190 195 200 205 210 215 220 225 230 235 240
0.81  0.85 185 190 195 200 205 210 215 220 225 230 235 240
0.86  0.90 190 195 200 205 210 215 220 225 230 235 240
0.91  0.95 195 200 205 210 215 220 225 230 235 240
0.96  1.00 200 205 210 215 220 225 230 235 240
1.01  1.05 205 210 215 220 225 230 235 240
1.06  1.10 210 215 220 225 230 235 240
1.11  1.15 215 220 225 230 235 240
1.16  1.20 220 225 230 235 240
1.21  1.25 225 230 235 240
1.26  1.30 230 235 240
1.31  1.35 235 240
1.36  1.40 240
EXHAUST
120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.00  0.02 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215
0.03  0.07 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220
0.08  0.12 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225
0.13  0.17 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230
0.18  0.20 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235
0.21  0.25
0.26  0.30 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.31  0.35 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.36  0.40 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.41  0.45 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.46  0.50 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.51  0.55 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.56  0.60 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.61  0.65 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.66  0.70 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.71  0.75 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.76  0.80 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.81  0.85 180 185 190 195 200 205 210 215 220 225 230 235 240
0.86  0.90 185 190 195 200 205 210 215 220 225 230 235 240
0.91  0.95 190 195 200 205 210 215 220 225 230 235 240
0.96  1.00 195 200 205 210 215 220 225 230 235 240
1.01  1.05 200 205 210 215 220 225 230 235 240
1.06  1.10 205 210 215 220 225 230 235 240
1.11  1.15 210 215 220 225 230 235 240
1.16  1.20 215 220 225 230 235 240
1.21  1.25 220 225 230 235 240
1.26  1.30 225 230 235 240
1.31  1.35 230 235 240
1.36  1.40 235 240
1.41  1.45 240
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3-17
ADJUSTING THE VALVE CLEARANCE /
SYNCHRONIZING THE THROTTLE BODIESCHK
ADJ
NOTE:
NOTE:
NOTE:
7. Install:

all removed parts
For installation, reverse the removal procedure.
SYNCHRONIZING THE THROTTLE BODIES
Prior to synchronizing the throttle bodies, the
valve clearance and the engine idling speed
should be properly adjusted and the ignition tim-
ing should be checked.
1. Stand the motorcycle on a level surface.
Place the motorcycle on a suitable stand.
2. Remove:

rider seat
Refer to “SEATS”.

fuel tank
Refer to “FUEL TANK”.
3. Remove:

synchronizing hoses
1
4. Install:

vacuum gauge
1
(onto the synchronizing hose)

digital tachometer
(near the spark plug)
Vacuum gauge
90890-03094, YU-08030
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3-18
SYNCHRONIZING THE THROTTLE BODIES
CHK
ADJ
NOTE:
CAUTION:
NOTE: 5. Install:

fuel tank
Refer to “FUEL TANK”.
6. Start the engine and let it warm up for several
minutes.
7. Measure:

engine idling speed
Out of specification
Adjust.
Refer to “ADJUSTING THE ENGINE IDLING
SPEED”.
Engine idling speed
1,150  1,250 r / min
8. Adjust:

throttle body synchronization
a. With throttle body #3 as standard, adjust
throttle bodies #1, #2, and #4 using the air
screws
1.

After each step, rev the engine two or three
times, each time for less than a second, and
check the synchronization again.

If the air screw is removed, turn the screw 3 / 4
turn in and be sure to synchronize the throttle
body.
Do not use the throttle valve adjusting
screws to adjust the throttle body synchro-
nization.
Vacuum pressure at engine
idling speed
22 kPa
(165 mmHg, 6.5 inHg)
The difference in vacuum pressure between
two throttle bodies should not exceed 1.33 kPa
(10 mmHg, 0.39 inHg).
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3-19
SYNCHRONIZING THE THROTTLE BODIES /
ADJUSTING THE EXHAUST GAS VOLUMECHK
ADJ
NOTE:
NOTE: 9. Measure:

engine idling speed
Out of specification
Adjust.
Make sure that the vacuum pressure is within
specification.
10. Stop the engine and remove the measuring
equipment.
11. Adjust:

throttle cable free play
Refer to “ADJUSTING THE THROTTLE
CABLE FREE PLAY”.
Throttle cable free play
(at the flange of the throttle grip)
3  5 mm (0.12  0.20 in)
13. Install:

synchronizing hoses

fuel tank
Refer to “FUEL TANK”.

rider seat
Refer to “SEATS”.
ADJUSTING THE EXHAUST GAS VOLUME
Be sure to set the carbon monoxide density to
standard, and then adjust the exhaust gas.
1. Turn the main switch to “OFF” and engine
stop switch “ON”.
2. While keeping the “SELECT” and “RESET”
buttons pressed simultaneously, turn “ON”
the main switch (keep them pressed for 8 se-
conds or more).
All indications on the meter disappear except
the clock and trip indications.
Letters “dIAG” appear on the clock LCD.
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