2004 YAMAHA YZF-R1S fuel filter

3-11
ADJUSTING THE VALVE CLEARANCE
CHK
ADJ
NOTE:
EAS00045
ENGINE
ADJUSTING THE VALVE CLEARANCE
The following procedure applies to all of the
valves.

Valve clearance adjustment should be made
on a cold engine, at room temperature.

When the valve clearance is to be measured or
adjusted, the piston must be at top dead center
(TDC) on the compression stroke.
1. Remove

rider seat
Refer to “SEATS”.

fuel tank
Refer to “FUEL TANK”.

air filter case
Refer to “AIR FILTER CASE”.

bottom cowlings

side cowlings
Refer to “COWLINGS”.

throttle body assembly
Refer to “THROTTLE BODIES” in chapter 7.

air cut-off valve
Refer to “AIR INDUCTION SYSTEM” in
chapter 7.

radiator

radiator fan motor
Refer to “RADIATOR” in chapter 6.
2. Remove

ignition coils

spark plugs

cylinder head cover

cylinder head cover gasket
Refer to “CAMSHAFT” in chapter 5.
3. Remove

pickup rotor cover
1
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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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5-5
Order Job / Part Q’ty Remarks
1
2Disconnecting the leads and hoses
Fuel tank
Air filter case
Throttle body assembly
Engine oil
Oil cooler
Air cut-off valve
Starter motor
Battery negative lead
Battery positive lead1
1Disconnect the parts in the order listed.
Refer to “FUEL TANK” in chapter 3.
Refer to “AIR FILTER CASE” in chapter 3.
Refer to “THROTTLE BODIES” in
chapter 7.
Drain.
Refer to “CHANGING THE ENGINE OIL”
in chapter 3.
Refer to “OIL COOLER” in chapter 6.
Refer to “AIR INDUCTION SYSTEM” in
chapter 7.
Refer to “STARTING SYSTEM” in
chapter 7.
ENGINEENG
LEADS AND HOSES
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6-1
Order Job / Part Q’ty Remarks
1
2
3
4
5Removing the radiator
Rider seat
Fuel tank
Air filter case
Side cowlings
Bottom cowling
Coolant
Fuse box stay
Coolant reservoir hose
Radiator
Radiator fan motor
Radiator inlet hose1
1
1
2
1Remove the parts in the order listed.
Refer to “AIR FILTER CASE” in chapter 3.
Drain.
Refer to “CHANGING THE COOLANT” in
chapter 3.
Disconnect.
Refer to “COWLINGS” in chapter 3.
Refer to “SEATS” in chapter 3.
10 Nm (1.0 m
kg, 7.2 ft
lb)
10 Nm (1.0 m
kg, 7.2 ft
lb)
5 Nm (0.5 m
kg, 3.6 ft
lb)
10 Nm (1.0 m
kg, 7.2 ft
lb)
RADIATORCOOL
EAS00454
COOLING SYSTEM
RADIATOR
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6-8
Order Job / Part Q’ty Remarks
1
2
3
4
5Removing the thermostat assembly
Rider seat
Fuel tank
Air filter case
Coolant
Thermostat assembly outlet hose
Thermostat assembly breather hose
Thermostat assembly
Thermostat assembly inlet hose
Band1
1
1
1
2Remove the parts in the order listed.
Refer to “SEATS” in chapter 3.
Refer to “FUEL TANK” in chapter 3.
Refer to “AIR FILTER CASE” in chapter 3.
Drain.
Refer to “CHANGING THE COOLANT” in
chapter3.
For installation, reverse the removal
procedure.
THERMOSTATCOOL
EAS00460
THERMOSTAT
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7-1
FUEL INJECTION SYSTEMFI
19Atmospheric pressure
sensor
20Fuel injection system
relay
21Engine trouble warning
light
22Lean angle cut-off
switch
23Air cut-off valve
13Coolant temperature
sensor
14Spark plug
15Cylinder identification
sensor
16Pressure regulator
17Battery
18ECU
1Ignition coil
2Air filter case
3Intake temperature
sensor
4Fuel delivery hose
5Fuel tank
6Fuel pump
7Fuel return hose
8Intake air presure sen-
sor
9Throttle position sen-
sor
10Fuel injector
11Catalytic converter
12Crankshaft position
sensor
FUEL INJECTION SYSTEM
FUEL INJECTION SYSTEM
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7-24
FUEL INJECTION SYSTEMFI
Intake air temperature sensor
resistance
2.21
2.69 kΩ at 20C (68F) Tester positive probe
brown / white
Tester negative probe
black / blue
1
2
12

Handle the intake air temperature sensor
with special care.

Never subject the intake air temperature sen-
sor to strong shocks. If the intake air temper-
ature sensor is dropped, replace it.
WARNING
Fault code No.22SymptomOpen or short circuit detected from the intake temperature sensor.
Used diagnostic code No. 05 (intake temperature sensor)
OrderInspection operation item and probable
causeOperation item and countermeasureReinstatement
method
1Connected condition of connector
Inspect the coupler for any pins that
may have pulled out.
Check the locking condition of the
coupler.If there is a malfunction, repair it and connect it
securely.
Intake temperature sensor coupler
Main wiring harness ECU coupler
Sub-wire harness couplerReinstated by
turning the
main switch
ON.
2Open or short circuit in wiring harness
and / or sub lead.Repair or replace if there is an open or short
circuit.
Between sensor coupler and ECU coupler
Black / Blue – Black / Blue
Brown / White – Brown / White
3Defective intake temperature sensor.Execute the diagnostic mode (Code No.05).
Replace if defective.
1. Remove the intake air temperature sensor
from the air filter case.
2. Connect the pocket tester (Ω  100) to the
intake air temperature sensor terminal as
shown.
3. Measure the intake air temperature sensor
resistance.
4. Is the intake air temperature sensor OK?
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