2004 YAMAHA YZF-R1S Service Manual

3-52
CHECKING AND ADJUSTING THE STEERING HEAD
CHK
ADJ
WARNING
NOTE:
NOTE: c. Loosen the lower ring nut
4 completely, then
tighten it to specification.
Do not overtighten the lower ring nut.
Lower ring nut
(final tightening torque)
18 Nm (1.8 m
kg, 13 ft
lb)
d. Check the steering head for looseness or
binding by turning the front fork all the way in
both directions. If any binding is felt, remove
the under bracket and check the upper and
lower bearings.
Refer to “STEERING HEAD” in chapter 4.
e. Install the rubber washer
3.
f. Install the upper ring nut
2.
g. Finger tighten the upper ring nut
2, then
align the slots of both ring nuts. If necessary,
hold the lower ring nut and tighten the upper
ring nut until their slots are aligned.
h. Install the lock washer
1.
Make sure the lock washer tabs
a sit correctly
in the ring nut slots
b.
5. Install:

upper bracket
Refer to “HANDLEBAR” and “STEERING
HEAD” in chapter 4.
6. Measure:

steering head tension
Make sure all of the cables and wires are prop-
erly routed.
a. Point the front wheel straight ahead.
b. Install a plastic locking tie
1 loosely around
the end of the handlebar as shown.
c. Hook a spring gauge
2 onto the plastic lock-
ing tie.
d. Hold the spring gauge at a 90 angle from the
handlebar, pull the spring gauge, and then
record the measurement when the handle-
bar starts to run.
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3-53
CHECKING AND ADJUSTING THE STEERING HEAD /
CHECKING THE FRONT FORKCHK
ADJ
WARNING
Steering head tension
200
500 g
e. Repeat the above procedure on the opposite
handlebar.
f. If the steering head tension is out of specifi-
cation (both handlebars should be within
specification), remove the upper bracket and
loosen or tighten the upper ring nut.
g. Reinstall the upper bracket and measure the
steering head tension again as described
above.
h. Repeat the above procedure until the steer-
ing head tension is within specification.
i. Grasp the bottom of the front fork legs and
gently rock the front fork.
Binding / looseness
Adjust the steering
head.
EAS00150
CHECKING THE FRONT FORK
1. Stand the motorcycle on a level surface.
Securely support the motorcycle so that
there is no danger of it falling over.
2. Check:

inner tube
1
Damage / scratches
Replace.

oil seal
2
Oil leakage
Replace.
3. Hold the motorcycle upright and apply the
front brake.
4. Check:

front fork operation
Push down hard on the handlebars several
times and check if the front fork rebounds
smoothly.
Rough movement
Repair.
Refer to “FRONT FORK” in chapter 4.
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3-54
ADJUSTING THE FRONT FORK LEGS
CHK
ADJ
WARNING
CAUTION:
a
b
CAUTION:
EAS00155
ADJUSTING THE FRONT FORK LEGS
The following procedure applies to both of the
front fork legs.

Always adjust both front fork legs evenly.
Uneven adjustment can result in poor han-
dling and loss of stability.

Securely support the motorcycle so that
there is no danger of it falling over.
Spring preload

Grooves are provided to indicate the ad-
justment position.

Never go beyond the maximum or mini-
mum adjustment positions.
1. Adjust:

spring preload
a. Turn the adjusting bolt
1 in direction a or
b.
Direction
Spring preload is
increased (suspension is
harder).
Direction
Spring preload is
decreased (suspension
is softer).
Adjusting positions
Minimum: 8
Standard: 4.5
Maximum: 1
Rebound damping
Never go beyond the maximum or minimum
adjustment positions.
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3-55
ADJUSTING THE FRONT FORK LEGS
CHK
ADJ
a
b
CAUTION:
a
b
1. Adjust:

rebound damping
a. Turn the adjusting screw
1 in direction a or
b.
Direction
Rebound damping is
increased (suspension is
harder).
Direction
Rebound damping is
decreased (suspension
is softer).
Adjusting positions
Minimum: 26 clicks in direction
b *
Standard: 10 clicks in direction
b *
Maximum: 1 clicks in direction
b *
* with the adjusting screw fully
turned-in direction
a
Compression damping
Never go beyond the maximum or minimum
adjustment positions.
1. Adjust:

compression damping
a. Turn the adjusting screw
1 in direction a or
b.
Direction
Compression damping is
increased (suspension is
harder).
Direction
Compression damping is
decreased (suspension
is softer).
Adjusting positions
Minimum: 25 clicks in direction
b *
Standard: 10 clicks in direction
b *
Maximum: 1 clicks in direction
b *
* with the adjusting screw fully
turned-in direction
a
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3-56
ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY
CHK
ADJ
WARNING
CAUTION:
a
b
CAUTION:
EAS00158
ADJUSTING THE REAR SHOCK
ABSORBER ASSEMBLY
Securely support the motorcycle so that
there is no danger of it falling over.
Spring preload
Never go beyond the maximum or minimum
adjustment positions.
1. Adjust:

spring preload
a. Adjust the spring preload with the special
wrench and extension bar included in the
owner’s tool kit.
b. Turn the adjusting ring
1 in direction a or
b.
c. Align the desired position on the adjusting
ring with the stopper
2.
Direction
Spring preload is
increased (suspension is
harder).
Direction
Spring preload is
decreased (suspension
is softer).
Adjusting positions
Minimum: 1
Standard: 4
Maximum: 9
Rebound damping
Never go beyond the maximum or minimum
adjustment positions.
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3-57
ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY
CHK
ADJ
a
b
CAUTION:
a
b
1. Adjust:

rebound damping
a. Turn the adjusting screw
1 in direction a or
b.
Direction
Rebound damping is
increased (suspension is
harder).
Direction
Rebound damping is
decreased (suspension
is softer).
Adjusting positions
Minimum: 20 clicks in direction
b *
Standard: 17 clicks in direction
b *
Maximum: 1 clicks in direction
b *
* with the adjusting screw fully
turned-in direction
a
Compression damping
Never go beyond the maximum or minimum
adjustment positions.
1. Adjust:

compression damping
a. Turn the adjusting screw
1 in direction a or
b.
Direction
Compression damping is
increased (suspension is
harder).
Direction
Compression damping is
decreased (suspension
is softer).
Adjusting positions
Minimum: 20 clicks in direction
b *
Standard: 12 clicks in direction
b *
Maximum: 1 clicks in direction
b *
* with the adjusting screw fully
turned-in direction
a
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3-58
CHECKING THE TIRES
CHK
ADJ
WARNING
WARNING
EAS00162
CHECKING THE TIRES
The following procedure applies to both of the
tires.
1. Check:

tire pressure
Out of specification
Regulate.

The tire pressure should only be checked
and regulated when the tire temperature
equals the ambient air temperature.

The tire pressure and the suspension must
be adjusted according to the total weight
(including cargo, rider, passenger and ac-
cessories) and the anticipated riding
speed.

Operation of an overloaded motorcycle
could cause tire damage, an accident or an
injury.
NEVER OVERLOAD THE MOTORCYCLE.
Basic
weight
(with oil
and a full
fuel tank)
193 kg (425 lb)
194 kg (428 lb) for CAL
Maximum
load*202 kg (445 lb)
201 kg (443 lb) for CAL
Cold tire
pressureFrontRear
Up to
90 kg
load*250 kPa
(2.5 kgf / cm2,
2.5 bar,
35.6 psi)
290 kPa
(2.9 kgf / cm2,
2.9 bar,
41.3 psi)
90 kg

maximum
load*250 kPa
(2.5 kgf / cm2,
2.5 bar,
35.6 psi)
290 kPa
(2.9 kgf / cm2,
2.9 bar,
41.3 psi)
High-
speed
riding250 kPa
(2.5 kgf / cm2,
2.5 bar,
35.6 psi)
290 kPa
(2.9 kgf / cm2,
2.9 bar,
41.3 psi)
* Total weight of rider, passenger, cargo and ac-
cessories
It is dangerous to ride with a worn-out tire.
When the tire tread reaches the wear limit,
replace the tire immediately.
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3-59
AB
CHECKING THE TIRES
CHK
ADJ
WARNING
WARNING
2. Check:

tire surfaces
Damage / wear
Replace the tire.
Minimum tire tread depth
1.6 mm (0.06 in)
1Tire tread depth
2Sidewall
3Wear indicator

Do not use a tubeless tire on a wheel de-
signed only for tube tires to avoid tire fail-
ure and personal injury from sudden defla-
tion.

When using a tube tire, be sure to install the
correct tube.

Always replace a new tube tire and a new
tube as a set.

To avoid pinching the tube, make sure the
wheel rim band and tube are centered in the
wheel groove.

Patching a punctured tube is not recom-
mended. If it is absolutely necessary to do
so, use great care and replace the tube as
soon as possible with a good quality re-
placement.
ATire
BWheel
Tube wheelTube tire only
T beless wheelTube or tubelessTubeless wheeltire
After extensive tests, the tires listed below
have been approved by Yamaha Motor Co.,
Ltd. for this model. The front and rear tires
should always be by the same manufacturer
and of the same design. No guarantee con-
cerning handling characteristics can be giv-
en if a tire combination other than one ap-
proved by Yamaha is used on this
motorcycle.
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