2004 YAMAHA YZF-R1S Service Manual

3-68
CHECKING THE FUSES
CHK
ADJ
WARNING
Pocket tester
90890-03112, YU-3112
b. If the pocket tester indicates “∞”, replace the
fuse.
3. Replace:

blown fuse
a. Set the main switch to “OFF”.
b. Install a new fuse of the correct amperage
rating.
c. Set on the switches to verify if the electrical
circuit is operational.
d. If the fuse immediately blows again, check
the electrical circuit.
Fuses
Amperage
ratingQ’ty
Main50 A1
Fuel injection
system15 A1
Headlight25 A1
Signaling
system10 A1
Ignition15 A1
Backup fuse
(odometer
and clock)
10 A1
Radiator
fan motor15 A2
Reserve25 A, 15 A,
10 A1
Never use a fuse with an amperage rating
other than that specified. Improvising or us-
ing a fuse with the wrong amperage rating
may cause extensive damage to the electri-
cal system, cause the lighting and ignition
systems to malfunction and could possibly
cause a fire.
4. Install:

front cowling inner panel (left)
Refer to “COWLINGS”.

rider seat
Refer to “SEATS”.
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3-69
A
A
B
B
B
REPLACING THE HEADLIGHT BULBS
CHK
ADJ
WARNING
EAS00183
REPLACING THE HEADLIGHT BULBS
The following procedure applies to both of the
headlight bulbs.
1. Disconnect:

headlight bulb cover
1

headlight coupler 2
Ahigh beam
Blow beam
2. Remove:

headlight bulb holder
1
Ahigh beam
Blow beam
3. Remove:

headlight bulb
Since the headlight bulb gets extremely hot,
keep flammable products and your hands
away from the bulb until it has cooled down.
4. Install:

headlight bulb
New
Secure the new headlight bulb with the head-
light bulb holder.
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3-70
REPLACING THE HEADLIGHT BULBS /
ADJUSTING THE HEADLIGHT BEAMSCHK
ADJ
CAUTION:
a
b
a
b
Avoid touching the glass part of the head-
light bulb to keep it free from oil, otherwise
the transparency of the glass, the life of the
bulb and the luminous flux will be adversely
affected. If the headlight bulb gets soiled,
thoroughly clean it with a cloth moistened
with alcohol or lacquer thinner.
5. Install:

headlight bulb holder
6. Install:

headlight bulb cover (high beam)

headlight bulb coupler (low beam)
7. Connect:

headlight coupler (high beam)

headlight cover (low beam)
EAS00185
ADJUSTING THE HEADLIGHT BEAMS
The following procedure applies to both of the
headlights.
1. Remove:

front cowling inner panels
Refer to “COWLINGS”.
2. Adjust:

headlight beam (vertically)
a. Turn the adjusting screw
1 in direction a or
b.
Direction
Headlight beam is raised.
DirectionHeadlight beam is
lowered.
3. Adjust:

headlight beam (horizontally)
a. Turn the adjusting screw
2 in direction a or
b.
Direction
Headlight beam moves to
the left.
DirectionHeadlight beam moves to
the right.
4. Install:

front cowling inner panels
Refer to “COWLINGS”.
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4-1
4
FRONT WHEEL AND BRAKE DISCSCHAS
Order Job / Part Q’ty Remarks
1
2
3
4
5
6
7
8
9
10Removing the front wheel and brake
discs
Side reflector (left and right)
Brake hose holder (left and right)
Side reflector bracket
Front brake caliper (left and right)
Front wheel axle pinch bolt
Front wheel axle bolt
Front wheel axle
Collar (left and right)
Front wheel
Front brake disc (left and right)2
2
2
2
4
1
1
2
1
2Remove the parts in the order listed.
Place the motorcycle on a suitable stand
so that the front wheel is elevated.
For installation, reverse the removal
procedure.
NOTE:
35 Nm (3.5 m
kg, 25 ft
lb)
6 Nm (0.6 m
kg, 4.3 ft
lb)
91 Nm (9.1 m
kg, 66 ft
lb)
20 Nm (2.0 m
kg, 13 ft
lb)
6 Nm (0.6 m
kg, 4.3 ft
lb)
18 Nm (1.8 m
kg, 13 ft
lb)
2 Nm (0.2 m
kg, 1.4 ft
lb)
2 Nm (0.2 m
kg, 1.4 ft
lb)
EAS00514
CHASSIS
FRONT WHEEL AND BRAKE DISCS
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4-2
FRONT WHEEL AND BRAKE DISCSCHAS
Order Job / Part Q’ty Remarks
Disassembling the front wheel
Oil seal (left and right)
Wheel bearing (left and right)
Spacer2
2
1Disassemble the parts in the order listed.
For assembly, reverse the disassembly
procedure.
1
2
3
EAS00518
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4-3
FRONT WHEEL AND BRAKE DISCSCHAS
WARNING
NOTE:
NOTE:
NOTE:
WARNING
EAS00521
REMOVING THE FRONT WHEEL
1. Stand the motorcycle on a level surface.
Securely support the motorcycle so that
there is no danger of it falling over.
Place the motorcycle on a suitable stand so that
the front wheel is elevated.
2. Remove:

left brake caliper

right brake caliper
Refer to “FRONT BRAKE CALIPERS”.
Do not apply the brake lever when removing the
brake calipers.
3. Elevate:

front wheel
Place the motorcycle on a suitable stand so that
the front wheel is elevated.
4. Loosen :

front wheel axle pinch bolt
5. Remove :

front wheel axle bolt

front wheel axle

front wheel
EAS00525
CHECKING THE FRONT WHEEL
1. Check:

wheel axle
Roll the wheel axle on a flat surface.
Bends
Replace.
Do not attempt to straighten a bent wheel
axle.
2. Check:

tire

front wheel
Damage / wear
Replace.
Refer to “CHECKING THE TIRES” and
“CHECKING THE WHEELS” in chapter 3.
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4-4
FRONT WHEEL AND BRAKE DISCSCHAS
NOTE:
CAUTION:
NOTE:
3. Measure:

radial wheel runout
1

lateral wheel runout 2
Over the specified limits
Replace.
Radial wheel runout limit
1.0 mm (0.04 in)
Lateral wheel runout limit
0.5 mm (0.02 in)
4. Check:

wheel bearings
Front wheel turns roughly or is loose
Re-
place the wheel bearings.

oil seals
Damage / wear
Replace.
5. Replace:

wheel bearings
New

oil seals
New
a. Clean the outside of the front wheel hub.
b. Remove the oil seals
1 with a flat-head
screwdriver.
To prevent damaging the wheel, place a rag
2
between the screwdriver and the wheel surface.
c. Remove the wheel bearings
3 with a gener-
al bearing puller.
d. Install the new wheel bearings and oil seals
in the reverse order of disassembly.
Do not contact the wheel bearing inner race
1 or balls 2. Contact should be made only
with the outer race
3.
Use a socket
4 that matches the diameter of
the wheel bearing outer race and oil seal.
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4-5
FRONT WHEEL AND BRAKE DISCSCHAS
NOTE:
EAS00533
CHECKING THE BRAKE DISCS
The following procedure applies to all of the
brake discs.
1. Check:

brake disc
Damage / galling
Replace.
2. Measure:

brake disc deflection
Out of specification
Correct the brake disc
deflection or replace the brake disc.
Brake disc deflection limit
(maximum)
Front : 0.1 mm (0.004 in)
Rear : 0.15 mm (0.006 in)
a. Place the motorcycle on a suitable stand so
that the wheel is elevated.
b. Before measuring the front brake disc deflec-
tion, turn the handlebars to the left or right to
ensure that the front wheel is stationary.
c. Remove the brake caliper.
d. Hold the dial gauge at a right angle against
the brake disc surface.
e. Measure the deflection 1.5 mm (0.06 in) be-
low the edge of the brake disc.
3. Measure:

brake disc thickness
Measure the brake disc thickness at a few
different locations.
Out of specification
Replace.
Brake disc thickness limit
(minimum)
Front : 4.0 mm (0.16 in)
Rear : 4.5 mm (0.18 in)
4. Adjust:

brake disc deflection
a. Remove the brake disc.
b. Rotate the brake disc by one bolt hole.
c. Install the brake disc.
Tighten the brake disc bolts in stages and in a
crisscross pattern.
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