2004 YAMAHA YZF-R1S lock

3-22
ADJUSTING THE THROTTLE CABLE FREE PLAY
CHK
ADJ
NOTE:
a
b
WARNING
EAS00056
ADJUSTING THE THROTTLE CABLE FREE
PLAY
Prior to adjusting the throttle cable free play, the
engine idling speed should be adjusted proper-
ly.
1. Check:

throttle cable free play
a
Out of specification
Adjust.
Throttle cable free play (at the
flange of the throttle grip)
3  5 mm (0.12  0.20 in)
2. Adjust:

throttle cable free play
Handlebar side
a. Loosen the locknut
1.
b. Turn the adjusting nut
2 in direction a or b
until the specified throttle cable free play is
obtained.
Direction
Throttle cable free play is
increased.
DirectionThrottle cable free play is
decreased.
c. Tighten the locknut.
After adjusting the throttle cable free play,
start the engine and turn the handlebars to
the right and to the left to ensure that this
does not cause the engine idling speed to
change.
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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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3-36
ADJUSTING THE EXUP CABLES
CHK
ADJ
EAS00101
ADJUSTING THE EXUP CABLES
1. Remove:

bottom cowlings
Refer to “COWLINGS”.
2. Remove:

EXUP valve pulley cover
1
3. Check:

EXUP system operation
a. Turn the main switch ON.
b. Check that the EXUP valve operates properly.
4. Check:

EXUP cable free play (at the EXUP valve
pulley)
a + b
Maximum EXUP cable free play
(at the EXUP valve pulley)
Less than 4 mm (0.16 in)
5. Adjust:

EXUP cable free play
a. Turn the main switch to “ON”.
b. Check the EXUP pulley position.
c. Projection of the EXUP pulley position is be-
tween
1 and 2.
d. Loosen the both locknuts
3.
e. Turn the both adjusting nuts
4 in or out.
f. Tighten the both locknuts.
6. Install:

EXUP valve pulley cover
EXUP valve pulley cover bolt
10 Nm (1.0 m
kg, 7.2 ft
lb)
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3-39
CHANGING THE COOLANT
CHK
ADJ
CAUTION:
EAS00105
CHANGING THE COOLANT
1. Remove:

bottom cowlings

side cowlings
Refer to “COWLINGS”.

rider seat
Refer to “SEATS”.
2. Remove:

coolant reservoir tank

coolant reservoir hose
3. Disconnect:

coolant reservoir cap
1
4. Drain:

coolant
(from the coolant reservoir tank)
5. Remove:

radiator cap
1
A hot radiator is under pressure. Therefore,
do not remove the radiator cap when the en-
gine is hot. Scalding hot fluid and steam may
be blown out, which could cause serious in-
jury. When the engine has cooled, open the
radiator cap as follows:
Place a thick rag or a towel over the radiator
cap and slowly turn the radiator cap coun-
terclockwise toward the detent to allow any
residual pressure to escape. When the his-
sing sound has stopped, press down on the
radiator cap and turn it counterclockwise to
remove.
The following procedure applies to all of the
coolant drain bolts and copper washers.
6. Remove:

coolant drain bolts
1
(along with the copper washers)
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3-43
ADJUSTING THE REAR BRAKE
CHK
ADJ
a
b
WARNING
WARNING
CAUTION:
EAS00110
ADJUSTING THE REAR BRAKE
1. Adjust:

brake pedal position
a. Loosen the locknut
1.
b. Turn the adjusting bolt
2 in direction a or b
until the specified brake pedal position is ob-
tained.
Direction
Brake pedal is raised.
DirectionBrake pedal is lowered.
After adjusting the brake pedal position,
check that the end of the adjusting bolt
c is
visible through the hole
d.
c. Tighten the locknut
1 to specification.
Locknut
16 Nm (1.6 m
kg, 12 ft
lb)
A soft or spongy feeling in the brake pedal
can indicate the presence of air in the brake
system. Before the vehicle is operated, the
air must be removed by bleeding the brake
system. Air in the brake system will consid-
erably reduce braking performance and
could result in loss of control and possibly
an accident. Therefore, check and, if neces-
sary, bleed the brake system.
After adjusting the brake pedal position,
make sure there is no brake drag.
2. Adjust:

rear brake light switch
Refer to “ADJUSTING THE REAR BRAKE
LIGHT SWITCH”.
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3-44
A
B
CHECKING THE BRAKE FLUID LEVEL
CHK
ADJ
NOTE:
WARNING
CAUTION:
NOTE:
EAS00115
CHECKING THE BRAKE FLUID LEVEL
1. Stand the motorcycle on a level surface.

Place the motorcycle on a suitable stand.

Make sure the motorcycle is upright.
2. Check:

brake fluid level
Below the minimum level mark
a
Add the
recommended brake fluid to the proper level.
Recommended brake fluid
DOT 4
AFront brake
BRear brake

Use only the designated brake fluid. Other
brake fluids may cause the rubber seals to
deteriorate, causing leakage and poor
brake performance.

Refill with the same type of brake fluid that
is already in the system. Mixing brake
fluids may result in a harmful chemical
reaction, leading to poor brake perfor-
mance.

When refilling, be careful that water does
not enter the brake fluid reservoir. Water
will significantly lower the boiling point of
the brake fluid and could cause vapor lock.
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean
up any spilt brake fluid immediately.
In order to ensure a correct reading of the brake
fluid level, make sure the top of the brake fluid
reservoir is horizontal.
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3-48
BLEEDING THE HYDRAULIC BRAKE SYSTEM /
ADJUSTING THE SHIFT PEDALCHK
ADJ
NOTE:
WARNING
NOTE:
a
b
Loosening the bleed screw will release the pres-
sure and cause the brake lever to contact the
throttle grip or the brake pedal to fully extend.
h. Tighten the bleed screw and then release the
brake lever or brake pedal.
i. Repeat steps (e) to (h) until all of the air
bubbles have disappeared from the brake
fluid in the plastic hose.
j. Tighten the bleed screw to specification.
Bleed screw
6 Nm (0.6 m
kg, 4.3 ft
lb)
k. Fill the brake fluid reservoir to the proper lev-
el with the recommended brake fluid.
Refer to “CHECKING THE BRAKE FLUID
LEVEL”.
After bleeding the hydraulic brake system,
check the brake operation.
After bleeding air, the brake fluid may ooze
around the thread section of each bleed screw.
This phenomenon does not show the leakage
but the brake fluid that has been accumulated in
the thread of screw while bleeding air. Please
wipe off to make the parts clean.
EAS00136
ADJUSTING THE SHIFT PEDAL
1. Adjust:

shift pedal position
a. Loosen both locknuts
1.
b. Turn the shift rod
2 in direction a or b to
obtain the correct shift pedal position.
Direction
Shift pedal is raised.
DirectionShift pedal is lowered.
c. Tighten both locknuts.
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3-49
ADJUSTING THE DRIVE CHAIN SLACK
CHK
ADJ
NOTE:
CAUTION:
WARNING
NOTE:
EAS00140
ADJUSTING THE DRIVE CHAIN SLACK
The drive chain slack must be checked at the
tightest point on the chain.
A drive chain that is too tight will overload
the engine and other vital parts, and one that
is too loose can skip and damage the swin-
garm or cause an accident. Therefore, keep
the drive chain slack within the specified
limits.
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 rear wheel is elevated.
2. Spin the rear wheel several times and find
the tightest position of drive chain.
3. Check:

drive chain slack
a
Out of specification
Adjust.
Drive chain slack
25
35 mm (0.98
1.38 in)
4. Adjust:

drive chain slack
a. Loosen the wheel axle nut
1.
b. Loosen both locknuts
2.
c. Turn both adjusting bolts
3 in direction a or
b until the specified drive chain slack is ob-
tained.
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