2004 YAMAHA YZF-R1S radiator

3-41
CHANGING THE COOLANT
CHK
ADJ
CAUTION:
NOTE:
Adding water instead of coolant lowers the
antifreeze content of the coolant. If water is
used instead of coolant check, and if nec-
essary, correct the antifreeze concentra-
tion of the coolant.

Use only distilled water. However, if dis-
tilled water is not available, soft water may
be used.

If coolant comes into contact with painted
surfaces, immediately wash them with wa-
ter.

Do not mix different types of antifreeze.
13. Install:

radiator cap
14. Fill:

coolant reservoir tank
(with the recommended coolant to the maxi-
mum level mark
a)
15. Install:

coolant reservoir cap
16. Start the engine, warm it up for several min-
utes, and then stop it.
17. Check:

coolant level
Refer to “CHECKING THE COOLANT LEV-
EL”.
Before checking the coolant level, wait a few
minutes until the coolant has settled.
18. Install:

rider seat
Refer to “SEATS”.

bottom cowlings

side cowlings
Refer to “COWLINGS”.
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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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5-11
Order Job / Part Q’ty Remarks
1
2
3
4Removing the cylinder head cover
Fuel tank
Side and bottom cowlings
Throttle body assembly
Radiator assembly
Air cut-off valve
Ignition coil
Spark plug
Cylinder head cover
Cylinder head cover gasket4
4
1
1Remove the parts in the order listed.
Refer to “FUEL TANK” in chapter 3.
Refer to “COWLINGS” in chapter 3.
Refer to “THROTTLE BODIES” in
chapter 7.
Refer to “RADIATOR” in chapter 3.
Refer to “AIR INDUCTION SYSTEM” in
chapter 7.
13 Nm (1.3 m
kg, 9.4 ft
lb)
8 Nm (0.8 m
kg, 5.7 ft
lb)
12 Nm (1.2 m
kg, 8.7 ft
lb)
CAMSHAFTENG
EAS00194
CAMSHAFT
CYLINDER HEAD COVER
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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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6-2
6
RADIATORCOOL
Order Job / Part Q’ty Remarks
6
7
8
9
10
11Radiator inlet pipe
Oil cooler outlet hose
Water pump breather hose
Radiator outlet hose
Water pump inlet pipe
O-ring1
1
1
1
1
1
For installation, reverse the removal
procedure.
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)
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6-3
RADIATORCOOL
NOTE:
EAS00455
CHECKING THE RADIATOR
1. Check:

radiator fins
Obstruction
Clean.
Apply compressed air to the rear of the radia-
tor.
Damage
Repair or replace.
Straighten any flattened fins with a thin, flat-
head screwdriver.
2. Check:

radiator hoses

radiator pipes
Cracks / damage
Replace.
3. Measure:

radiator cap opening pressure
Below the specified pressure
Replace the
radiator cap.
Radiator cap opening pressure
108
137 kPa
(1.08
1.37 kg / cm
2,
1.0
1.3 bar, 15.6
19.9 psi)
a. Install the radiator cap tester
1 and radiator
cap tester adapter
2 to the radiator cap 3.
Radiator cap tester
90890-01325, YU-24460-01
Radiator cap tester adapter
90890-01352, YU-33984
b. Apply the specified pressure for ten seconds
and make sure there is no drop in pressure.
4. Check:

radiator fan
Damage
Replace.
Malfunction
Check and repair.
Refer to “COOLING SYSTEM” in chapter 8.
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6-4
RADIATORCOOL
EAS00456
INSTALLING THE RADIATOR
1. Fill:

cooling system
(with the specified amount of the recom-
mended coolant)
Refer to “CHANGING THE COOLANT” in
chapter 3.
2. Check:

cooling system
Leaks
Repair or replace any faulty part.
3. Measure:

radiator cap opening pressure
Below the specified pressure
Replace the
radiator cap.
Refer to “CHECKING THE RADIATOR”.
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6-7
OIL COOLERCOOL
63 Nm (6.3 m
kg, 46 ft
lb)
NOTE:
EAS00458
CHECKING THE OIL COOLER
1. Check:

oil cooler
Cracks / damage
Replace.
2. Check:

oil cooler inlet hose

oil cooler outlet hose
Cracks / damage / wear
Replace.
EAS00459
INSTALLING THE OIL COOLER
1. Clean:

mating surfaces of the oil cooler and the
crankcase
(with a cloth dampened with lacquer thinner)
2. Install:

O-ring
New

oil cooler
1

washer 2 New

bolt
3

Before installing the oil cooler, lubricate the oil
cooler bolt and O-ring with a thin coat of engine
oil.

Make sure that the O-ring is positioned proper-
ly.

Align the projection
a on the oil cooler with the
slot
b in the crankcase.
3. Fill:

cooling system
(with the specified amount of the recom-
mended coolant)
Refer to “CHANGING THE COOLANT” in
chapter 3.

crankcase
(with the specified amount of the recom-
mended engine oil)
Refer to “CHANGING THE ENGINE OIL” in
chapter 3.
4. Check:

cooling system
Leaks
Repair or replace any faulty part.
5. Measure:

radiator cap opening pressure
Below the specified pressure
Replace the
radiator cap.
Refer to “CHECKING THE RADIATOR”.
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