2004 YAMAHA YZF-R1S fuel

1-12
SPECIAL TOOLS
GEN
INFO
Tool No.Tool name / FunctionIllustration
90890-04101
Valve lapper
This tool is needed to remove and install
the valve lifter.
90890-03176
YM-03176
Fuel pressure adapter
This tool is needed to measure fuel pres-
sure.
90890-03153
YU-03153
Pressure gauge
This tool is used to measure fuel pressure.
90890-04143
YM-04143
Camshaft wrench
This tool is used to hold and rotate the cam-
shaft sprocket.
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2-1
GENERAL SPECIFICATIONSSPEC
SPECIFICATIONS
GENERAL SPECIFICATIONS
ItemStandardLimit
Model code5VY4 (USA), 5VY5 (CAL)



Dimensions
Overall length
Overall width
Overall height
Seat height
Wheelbase
Minimum ground clearance
Minimum turning radius
2,065 mm (8.13 in)
720 mm (28.3 in)
1,105 mm (43.5 in)
835 mm (32.9 in)
1,395 mm (54.9 in)
135 mm (5.31 in)
3,400 mm (133.9 in)



























Weight
Wet (with oil and a full fuel tank)
Maximum load (except motorcycle)
193 kg (425 lb) (USA)
194 kg (428 lb) (CAL)
202 kg (445 lb) (USA)
201 kg (443 lb) (CAL)







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2-2
ENGINE SPECIFICATIONSSPEC
2
ENGINE SPECIFICATIONS
ItemStandardLimit
Engine
Engine type
Displacement
Cylinder arrangement
Bore
stroke
Compression ratio
Engine idling speed
Vacuum pressure at engine idling
speed
Standard compression pressure
(at sea level)
Liquid-cooled, 4-stroke, DOHC
998 cm3 (60.90 cu.in)
Forward-inclined parallel 4-cylinder
77.0
53.6 mm (3.03
2.11 in)
12.4 : 1
1,150  1,250 r / min
22 kPa (165 mmHg, 6.5 inHg)
1,480 kPa (14.80 kg / cm
2,14.80 bar,
210.5 psi) at 350 r / min
































Fuel
Recommended fuel
Fuel tank capacity
Total (including reserve)
Reserve only
Premium unleaded gasoline only
18 L (3.96 Imp gal, 4.76 US gal)
3.4 L (0.75 Imp gal, 0.90 US gal)











Engine oil
Lubrication system
Recommended oil
Quantity
Total amount
Without oil filter cartridge
replacement
With oil filter cartridge replacement
Oil pressure
Engine oil temperature
Relief valve opening pressure
Wet sump
At 5C (40F) or higher
Yamalube 4 (20W40) or SAE 20W40
type SE motor oil
At 15C (60F) or lower
Yamalube 4 (10W30) or SAE 10W30
type SE motor oil
3.8 L (3.35 Imp qt, 4.02 US qt)
2.9 L (2.55 Imp qt, 3.07 US qt)
3.1 L (2.73 Imp qt, 3.28 US qt)
230 kPa at 5,000 r / min
(2.3 kg / cm
2 at 5,000 r / min)
(2.3 bar at 5,000 r / min)
(32.7 psi at 5,000 r / min)
100C (212F)
600  680 kPa (6.0  6.8 kg / cm
2,
6.0  6.8 bar, 87.0  98.6 psi)
























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2-10
ENGINE SPECIFICATIONSSPEC
ItemStandardLimit
Transmission
Transmission type
Primary reduction system
Primary reduction ratio
Secondary reduction system
Secondary reduction ratio
Operation
Gear ratios
1st gear
2nd gear
3rd gear
4nd gear
5th gear
6th gear
Max. main axle runout
Max. drive axle runout
Constant mesh, 6-speed
Spur gear
65 / 43 (1.512)
Chain drive
45 / 17 (2.647)
Left-foot operation
38 / 15 (2.533)
33 / 16 (2.063)
37 / 21 (1.762)
35 / 23 (1.522)
30 / 22 (1.364)
33 / 26 (1.269)























































0.08 mm
(0.0032 in)
0.08 mm
(0.0032 in)
Shifting mechanism
Shift mechanism type
Max. shift fork guide bar bending
Shift drum / Guide bar







0.10 mm
(0.0039 in)
Air filter typeOil coated paper element



Fuel pump
Pump type
Model (manufacturer)
Output pressure
Electrical
5PW (DENSO)
294 kPa (2.94 kg / cm
2, 2.94 bar, 42.6 psi)












Throttle position sensor
Resistance
Output voltage (at idle)
4.9  5.1 kΩ at 20C (68F)
0.63  0.73 V



Throttle bodies
Model (manufacturer)
quantity
Intake vacuum pressure
Throttle cable free play (at the flange
45EIDW (MIKUNI)
2
22 kPa (165 mmHg, 6.4966 inHg)
3  5 mm (0.12  0.20 in)











of the throttle grip)
ID mark
Throttle valve size
5VY1 00 (USA)
5VY5 10 (CAL)
#100







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2-16
ELECTRICAL SPECIFICATIONSSPEC
ItemStandardLimit
Indicator light
(voltage / wattage
quantity)
Neutral indicator light
High beam indicator light
Oil level warning light
Turn signal indicator light
Fuel level warning light
Coolant temparture indicator light
Engine trouble warning light
Shift timing indicator light
LED
1
LED
1
LED
1
LED
2
LED
1
LED
1
LED
1
LED
1































Electric starting system
System type
Starter motor
Model (manufacturer)
Power output
Brushes
Overall length
Spring force
Armature coil resistance
Commutator diameter
Mica undercut
Constant mesh
5VY (YAMAHA)
0.9 kW
10.8 mm (0.43 in)
5.28  7.92 N (538  808 g,
18.99  28.48 oz)
0.0090  0.0110 Ω at 20C (68F)
24.5 mm (0.96 in)
1.5 mm (0.06 in)











3.6 mm
(0.14 in)








23.5 mm
(0.93 in)




Starter relay
Model (manufacturer)
Amperage
Coil resistance
2768079-A (JIDECO)
180 A
4.18  4.62 Ω at 20C (68F)











Horn
Horn type
Model (manufacturer)
quantity
Max. amperage
Performance
Coil resistance
Plane
YF-12 (NIKKO)
1
3 A
105  113 db / 2 m
1.15  1.25 Ω at 20C (68F)



















Turn signal relay
Relay type
Model (manufacturer)
Self-cancelling device built-in
Turn signal blinking frequency
Wattage
Full transistor
FE218BH (DENSO)
No
75  95 cycles / min.
21 W
2 + 3.4 W



















Oil level switch
Model (manufacturer)
5VY (SOMIC ISHIKAWA)



EXUP servo motor
Model (manufacturer)
5VY (YAMAHA)



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2-17
ELECTRICAL SPECIFICATIONSSPEC
ItemStandardLimit
Fuses (amperage
quantity)
Main fuse
Fuel injection system fuse
Headlight fuse
Signaling system fuse
Ignition fuse
Radiator fan motor fuse
Backup fuse (odometer and clock)
Reserve fuse
50 A
1
15 A
1
25 A
1
10 A
1
15 A
1
15 A
2
10 A
1
25 A, 15 A, 10 A
1































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2-23
TIGHTENING TORQUESSPEC
See NOTE 2 CHASSIS TIGHTENING TORQUES
ItemThreadTighteningRemarksItemsizeNmm
kgft
lbRemarks
Upper bracket and outer tubeM8262.619
Upper bracket and steering stem nutM2811 311.382
Handlebar and outer tubeM8171.712
Handlebar and upper bracketM6131.39
Steering shaft and ring nutM30181.813See NOTE 1
Outer tube and under bracketM8232.317
Main switch and upper bracketM8262.619
Front brake master cylinder cap stopperM41.20.120.9
Front brake hose union boltsM10303.022
Front brake master cylinder and bracketM6131.39
Meter assembly and front cowling stay—1.30.130.9
Headlight and front cowling stay—0.80.080.6
Front cowling and headlight assembly—1.50.151.1
Cover 7, 8 and frameM650.53.6
Under cowling and engineM650.53.6
Windshield and front cowlingM50.40.040.3
Duct and console panelM51.30.130.9
End grip and handlebarM640.42.9
Horn bracket and under bracketM640.42.9
Coolant reservoir tank and frameM650.53.6
Engine mount front (left and right)M10454.533
Engine mount rear upperM10515.137
Engine mount rear underM10515.137
Engine mount rear adjust boltM1670.75.1
Catalyst pipe stay and frameM10444.432
Clutch cable lock nut (engine side)M870.75.1
Main frame and rear frameM10414.130
Throttle cable adjust nut (throttle body side)M650.53.6
Cover 2 and plate—0.80.080.6
Pivot shaft and nutM1810510.576
Connecting rod and frameM10444.432
Relay arm and connecting rodM10444.432
Relay arm and swingarmM10444.432
Rear shock absorber and relay armM10444.432
Rear shock absorber and upper bracketM10444.432
Upper bracket and frameM14929.267
Seal guardM670.75.1
Drive chain caseM670.75.1
Chain puller adjust nutM8161.612
Fuel tank and fuel pump assemblyM540.42.9
Fuel tank stay (front side) and frameM670.75.1
Fuel tank and fuel tank stay (front side)M670.75.1
Fuel tank stay (rear side) and rear frameM670.75.1
Side cover and fuel tankM50.40.040.3
Rider seat and frameM670.75.1
Seat lock plate and rear frameM6101.07
Side cover (rear side) and frameM540.42.9
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2-39
E Clamp the clamp upper end
along the line of lower end of the
hose clamp assembly. Point the
tip of the clamp (surplus section)
to the front side of the vehicle.
Clutch cable is what the clamp
fastens.
F The clutch cable doesn’t project
outside the water hose and the
cylinder head in the box part in
the figure.
G To the engine
H Clamp behind the bracket 3.17Throttle body lead
A Clamp it after passing between
the frame and radiator stay.
Point the tip of the clamp (exces-
sive part) to the front side of the
vehicle. Fasten the right handle-
bar switch lead with a clamp.
B To the wire harness
C The clutch cable positioning
guide should be above the upper
end of the clamp. Fasten the
clutch cable with a clamp. (Refer
to )
D Position relation between the
clamp and guide.
M
CABLE ROUTINGSPEC
1Wire harness
2Crankshaft position sensor lead
3Heat protector
4Right handlebar switch lead
5Positioning guide
6Rear brake light switch lead
7Coolant reservoir tank
8Speed sensor lead
9Clutch cable
10Radiator
11Oil cooler outlet hose
12Coolant reservoir tank drain
hose
13Breather pipe
14Fuel tank drain hose
15A.C. magneto lead
16Wire harness
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