2004 YAMAHA YZF-R1S oil pressure

2-43
33Throttle body side cap
34Mud guard
35Turn signal light lead
36License plate light lead
37Rear fender rib
38Speed sensor lead
39Rear brake light switch lead
40Rear frame
41Swingarm bracket
42Main fuse lead
43Starting circuit cut-off relay lead
44Turn signal light relay lead
45Starter relay lead
46Main fuse lead (To the battery
positive lead)
47Right handlebar switch lead
17Battery negative lead
18Starter motor lead
19A.C.magneto lead
20Oil level switch lead
21Sidestand switch lead
22Throttle body lead
23Coolant reservoir tank drain hose
24Fuel tank drain hose
25Cover 7
26Radiator fan motor lead (left)
27Radiator fan motor lead (right)
28Wire harness
29Pipe 3
30Frame
31Coolant reservoir tank hose
32Thermo stat assembly breather
hose
CABLE ROUTINGSPEC
1Heat protector
2Crankshaft position sensor lead
3Neutral switch lead
4Ground lead
5Coolant reservoir tank
6Battery positive lead
7Starter relay
8Turn signal relay
9Main fuse
10Lean angle cut-off switch
11Atmospheric pressure sensor
12Tail / brake light lead
13Rear fender
14Seat lock cable
15Anti safety alarm coupler
16Starting circuit cut-off relay
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3-24
CHECKING THE SPARK PLUGS /
MEASURING THE COMPRESSION PRESSURECHK
ADJ
13 Nm (1.3 m
kg, 9.4 ft
lb)
NOTE:
NOTE:
CAUTION:
8. Install:

spark plugs

ignition coils
Before installing the spark plug, clean the spark
plug and gasket surface.
9. Install:

radiator upper bolts

radiator lower bolt
Refer to “RADIATOR” in chapter 6.
10. Install:

side cowlings

bottom cowlings
Refer to “COWLINGS”.
EAS00065
MEASURING THE COMPRESSION
PRESSURE
The following procedure applies to all of the cyl-
inders.
Insufficient compression pressure will result in a
loss of performance.
1. Measure:

valve clearance
Out of specification
Adjust.
Refer to “ADJUSTING THE VALVE CLEAR-
ANCE”.
2. Start the engine, warm it up for several min-
utes, and then turn it off.
3. Remove:

ignition coils

spark plugs
Before removing the spark plugs, use com-
pressed air to blow away any dirt accumu-
lated in the spark plug wells to prevent it
from falling into the cylinders.
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3-26
MEASURING THE COMPRESSION PRESSURE /
CHECKING THE ENGINE OIL LEVELCHK
ADJ
13 Nm (1.3 m
kg, 9.4 ft
lb)
NOTE: d. If the compression pressure is below the
minimum specification, pour a teaspoonful of
engine oil into the spark plug bore and mea-
sure again.
Refer to the following table.
Compression pressure
(with oil applied into the cylinder)
ReadingDiagnosis
Higher than
without oilPiston ring(s) wear
or damage

Repair.
Same as without
oilPiston, valves,
cylinder head
gasket or piston
possibly defective

Repair.
6. Install:

spark plug
7. Install:

ignition coils
EAS00069
CHECKING THE ENGINE OIL LEVEL
1. Stand the motorcycle on a level surface.

Place the motorcycle on a suitable stand.

Make sure the motorcycle is upright.
2. Start the engine, warm it up for several min-
utes, and then turn it off.
3. Check:

engine oil level
The engine oil level should be between the
minimum level mark
a and maximum level
mark
b.
Below the minimum level mark
Add the
recommended engine oil to the proper level.
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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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3-50
a
b
ADJUSTING THE DRIVE CHAIN SLACK /
LUBRICATING THE DRIVE CHAINCHK
ADJ
NOTE:
DirectionDrive chain is tightened.
DirectionDrive chain is loosened.
To maintain the proper wheel alignment, adjust
both sides evenly.
d. Tighten both locknuts to specification.
Locknut
16 Nm (1.6 m
kg, 12 ft
lb)
e. Tighten the wheel axle nut to specification.
Wheel axle nut
150 Nm (15 m
kg, 108 ft
lb)
EAS00142
LUBRICATING THE DRIVE CHAIN
The drive chain consists of many interacting
parts. If the drive chain is not maintained proper-
ly, it will wear out quickly. Therefore, the drive
chain should be serviced, especially when the
motorcycle is used in dusty areas.
This motorcycle has a drive chain with small
rubber O-rings between each side plate. Steam
cleaning, high-pressure washing, certain sol-
vents, and the use of a coarse brush can dam-
age these O-rings. Therefore, use only kero-
sene to clean the drive chain. Wipe the drive
chain dry and thoroughly lubricate it with engine
oil or chain lubricant that is suitable for O-ring
chains. Do not use any other lubricants on the
drive chain since they may contain solvents that
could damage the O-rings.
Recommended lubricant
Engine oil or chain lubricant
suitable for O-ring chains
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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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