2004 YAMAHA YZF-R1S Service Manual

3-28
CHANGING THE ENGINE OIL
CHK
ADJ
NOTE:
CAUTION:
EAS00074
CHANGING THE ENGINE OIL
1. Start the engine, warm it up for several min-
utes, and then turn it off.
2. Place a container under the engine oil drain
bolt.
3. Remove:

bottom cowlings
Refer to “COWLINGS”.
4. Remove:

engine oil filler cap
1
Remove the engine oil filler cap 1 with the spe-
cial wrench
2 and cover 3.
5. Remove:

engine oil drain bolt
1
(along with the gasket)
6. Drain:

engine oil
(completely from the crankcase)
7. If the oil filter cartridge is also to be replaced,
perform the following procedure.
a. Remove the oil filter cartridge
1 with an oil
filter wrench
2.
Oil filter wrench
90890-01426, YU-38411
b. Lubricate the O-ring
3 of the new oil filter
cartridge with a thin coat of engine oil.
Make sure the O-ring
3 is positioned cor-
rectly in the groove of the oil filter cartridge.
c. Tighten the new oil filter cartridge to specifi-
cation with an oil filter wrench.
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3-29
CHANGING THE ENGINE OIL /
MEASURING THE ENGINE OIL PRESSURECHK
ADJ
43 Nm (4.3 m
kg, 31 ft
lb)
CAUTION:
Oil filter cartridge
17 Nm (1.7 m
kg, 12 ft
lb)
8. Replace:

engine oil drain bolt gasket
New
9. Install:

engine oil drain bolt
(along with the new gasket)
10. Fill:

crankcase
(with the specified amount of the recom-
mended engine oil)
Quantity
Total amount
3.8 L (3.35 Imp qt, 4.02 US qt)
Without oil filter cartridge
replacement
2.9 L (2.55 Imp qt, 3.07 US qt)
With oil filter cartridge
replacement
3.1 L (2.73 Imp qt, 3.28 US qt)
11. Install:

engine oil filler cap

bottom cowlings
Refer to “COWLINGS”.
12. Start the engine, warm it up for several min-
utes, and then turn it off.
EAS00077
MEASURING THE ENGINE OIL PRESSURE
1. Check:

engine oil level
Below the minimum level mark
a
Add the
recommended engine oil to the proper level.
2. Start the engine, warm it up for several min-
utes, and then turn it off.
When the engine is cold, the engine oil will
have a higher viscosity, causing the engine
oil pressure to increase. Therefore, be sure
to measure the engine oil pressure after
warming up the engine.
3. Remove:

bottom cowlings
Refer to “COWLINGS”.
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3-30
MEASURING THE ENGINE OIL PRESSURE
CHK
ADJ
WARNING
NOTE: 4. Remove:

oil gallery bolt
1
The engine, muffler and engine oil are ex-
tremely hot.
5. Install:

oil pressure gauge
1

adapter 2
Pressure gauge
90890-03153, YU-03153
Oil pressure adapter
90890-03139
6. Measure:

engine oil pressure
(at the following conditions)
Engine oil pressure
230 kPa
(2.3 kg / cm
2, 2.3 bar, 32.71 psi)
Engine speed
Approx. 5,000 r / min
Engine oil temperature
100C (212F)
Regarding the oil pressure as its own data may
fluctuate depending on the oil temperature and
viscosity, the oil pressure may fluctuate when
measuring. The following data should be used
only as a reference when measuring the engine
oil pressure.
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3-31
MEASURING THE ENGINE OIL PRESSURE /
ADJUSTING THE CLUTCH CABLE FREE PLAYCHK
ADJ
8 Nm (0.8 m
kg, 5.8 ft
lb)
CAUTION:
c
b
NOTE:Engine oil pressure
Possible causes
Below
ifi i
Faulty oil pump
specificationClogged oil filter
Leaking oil
passage
Broken or
damaged oil seal
Above
specificationLeaking oil
passage
Faulty oil filter
Oil viscosity too
high
7. Install:

oil gallery bolt
1
Be carful to tighten too much.
8. Install:

bottom cowlings
Refer to “COWLINGS”.
EAS00078
ADJUSTING THE CLUTCH CABLE FREE
PLAY
1. Check:

clutch cable free play
a
Out of specification
Adjust.
Clutch cable free play (at the
end of the clutch lever)
10  15 mm (0.39  0.59 in)
2. Adjust:

clutch cable free play
Handlebar side
a. Turn the adjusting dial
1 in direction b or c
until the specified clutch cable free play is ob-
tained.
Direction
Clutch cable free play is
increased.
DirectionClutch cable free play is
decreased.
If the specified clutch cable free play cannot be
obtained on the handlebar side of the cable, use
the adjusting nut on the engine side.
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3-32
ADJUSTING THE CLUTCH CABLE FREE PLAY /
REPLACING THE AIR FILTER ELEMENTCHK
ADJ
a
b
NOTE: Engine side
a. Loosen the locknut
1.
b. Turn the adjusting nut
2 in direction a or b
until the specified clutch cable free play is ob-
tained.
Direction
Clutch cable free play is
increased.
DirectionClutch cable free play is
decreased.
c. Tighten the locknuts.
Lock nut
7Nm (0.7 m
kg, 5.1 ft
lb)
EAS00086
REPLACING THE AIR FILTER ELEMENT
1. Remove:

rider seat
Refer to “SEATS”.

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

air filter case cover
1
3. Check:

air filter element
1
Damage
Replace.
Replace the air filter element at periodic inter-
vals of 40,000 km travel.
The air filter needs more frequent service if you
are riding in unusuallu wet or dusty areas.
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3-33
REPLACING THE AIR FILTER ELEMENT /
CHECKING THE FUEL AND BREATHER HOSESCHK
ADJ
CAUTION:
NOTE:
NOTE: 4. Install:

air filter case cover
Never operate the engine without the air fil-
ter element installed. Unfiltered air will
cause rapid wear of engine parts and may
damage the engine. Operating the engine
without the air filter element will also affect
the throttle bodies tuning, leading to poor
engine performance and possible overheat-
ing.
When installing the air filter element into the air
filter case cover, make sure their sealing sur-
faces are aligned to prevent any air leaks.
5. Install:

fuel tank
Refer to “FUEL TANK”.

rider seat
Refer to “SEATS”.
EAS00096
CHECKING THE FUEL AND BREATHER
HOSES
The following procedure applies to all of the fuel
and breather hoses.
1. Remove:

rider seat
Refer to “SEATS”.

fuel tank
Refer to “FUEL TANK”.
2. Check:

breather hose
1

fuel hose 2
Cracks / damage
Replace.
Loose connection
Connect properly.
Before removing the fuel hoses, place a few
rags in the area under where it will be removed.
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3-34
CHECKING THE FUEL AND BREATHER HOSES /
CHECKING THE CRANKCASE BREATHER HOSECHK
ADJ
CAUTION:
CAUTION:
CAUTION:
3. Install:

fuel tank
Refer to “FUEL TANK”.

rider seat
Refer to “SEATS”.
To install the fuel tank, check that the breath-
er hose is not folded or pinched by the fuel
tank.
EAS00098
CHECKING THE CRANKCASE BREATHER
HOSE
1. Remove:

rider seat
Refer to “SEATS”.

fuel tank
Refer to “FUEL TANK”.
2. Check:

crankcase breather hose
1
Cracks / damage
Replace.
Loose connection
Connect properly.
Make sure the crankcase breather hose is
routed correctly.
3. Install:

fuel tank
Refer to “FUEL TANK”.

rider seat
Refer to “SEATS”.
To install the fuel tank, check that the breath-
er hose is not folded or pinched by the fuel
tank.
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3-35
CHECKING THE EXHAUST SYSTEM
CHK
ADJ
WARNING
NOTE:
EAS00099
CHECKING THE EXHAUST SYSTEM
The following procedure applies to all of the ex-
haust pipes and gaskets.
Do not touch the muffler bracket until the ex-
haust system has cooled.
1. Check:

exhaust pipe
1

exhaust valve pipe 2

muffler 3
Cracks / damage
Replace.

gaskets
4
Exhaust gas leaks
Replace.
2. Check:

tightening torque
Exhaust pipe nut
5
20 Nm (2.0 m
kg, 14 ft
lb)
Exhaust pipe and exhaust valve
pipe bolt
6
10 Nm (1.0 m
kg, 7.2 ft
lb)
Catalyst pipe assembly bolt
7
20 Nm (2.0m
kg, 14 ft
lb)
Catalyst pipe assembly and
muffler bolt
8
20 Nm (2.0 m
kg, 14 ft
lb)
Muffler cover
9
10 Nm (1.0 m
kg, 7.2 ft
lb)
Install the EXUP cable in parallel without twist-
ing its upper
10 and lower sides 11.

black metal
10 is upper.

white metal
11 is lower.
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