2004 YAMAHA YZF-R1S seats

3-63
Relationship between the open-circuit voltage
and the charging time at 20C
Open-circuit voltage (V)
These values vary with the temperature, the condition of
the battery plates, and the electrolyte level. 13.0
12.5
12.0
11.5
5 6.5 10
Charging time (hours)
Ambient
temperature
20C
Open-circuit voltage (V)
Charging condition of the battery (%)
CHECKING AND CHARGING THE BATTERY
CHK
ADJ
NOTE:
CAUTION:
NOTE:
Since MF batteries are sealed, it is not possible
to check the charge state of the battery by mea-
suring the specific gravity of the electrolyte.
Therefore, the charge of the battery has to be
checked by measuring the voltage at the battery
terminals.
1. Remove:

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

battery leads
(from the battery terminals)
First, disconnect the negative battery lead
1, and then the positive battery lead 2.
3. Remove:

battery
4. Check:

battery charge
a. Connect a pocket tester to the battery termi-
nals.
Pocket tester
90890-03112, YU-3112
Positive tester probe

positive battery terminal
Negative tester probe

negative battery terminal

The charge state of an MF battery can be
checked by measuring its open-circuit voltage
(i.e., the voltage when the positive battery ter-
minal is disconnected).

No charging is necessary when the open-cir-
cuit voltage equals or exceeds 12.8 V.
b. Check the charge of the battery, as shown in
the charts and the following example.
Example
c. Open-circuit voltage = 12.0 V
d. Charging time = 6.5 hours
e. Charge of the battery = 20
30%
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3-67
CHECKING AND CHARGING THE BATTERY /
CHECKING THE FUSESCHK
ADJ
CAUTION:
CAUTION:
NOTE: 6. Install:

battery
7. Connect:

battery leads
(to the battery terminals)
First, connect the positive battery lead
1,
and then the negative battery lead
2.
8. Check:

battery terminals
Dirt
Clean with a wire brush.
Loose connection
Connect properly.
9. Lubricate:

battery terminals
Recommended lubricant
Dielectric grease
10. Install:

rider seat
Refer to “SEATS”.
EAS00181
CHECKING THE FUSES
The following procedure applies to all of the
fuses.
To avoid a short circuit, always set the main
switch to “OFF” when checking or replacing
a fuse.
1. Remove:

front cowling inner panel (left)
Refer to “COWLINGS”.

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

fuse
a. Connect the pocket tester to the fuse and
check the continuity.
Set the pocket tester selector to “Ω  1”.
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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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5-2
5
Order Job / Part Q’ty Remarks
1
2
3
4
5
6
7
8
9
10Removing the exhaust pipe
Rider seat and passenger seat
Fuel tank
Side cowlings and bottom cowlings
EXUP pulley cover
EXUP cable
Exhaust pipe assembly
Exhaust pipe gasket
Exhaust valve pipe gasket
Exhaust valve pipe assembly
Catalyst pipe assembly
Gasket
Muffler
Gasket1
2
1
4
1
1
1
1
2
2Remove the parts in the order listed.
Refer to “SEATS” in chapter 3.
Refer to “FUEL TANK” in chapter 3.
Refer to “COWLINGS” in chapter 3.
10 Nm (1.0 m
kg, 7.2 ft
lb)
10 Nm (1.0 m
kg, 7.2 ft
lb)
10 Nm (1.0 m
kg, 7.2 ft
lb)
20 Nm (2.0 m
kg, 14 ft
lb)
20 Nm (2.0 m
kg, 14 ft
lb)
20 Nm (2.0 m
kg, 14 ft
lb)
23 Nm (2.3 m
kg, 17 ft
lb)
ENGINEENG
EXHAUST PIPE
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5-23
CYLINDER HEADENG
NOTE:
NOTE:
NOTE:
EAS00222
REMOVING THE CYLINDER HEAD
1. Remove:

intake camshaft

exhaust camshaft
Refer to “REMOVING THE CAMSHAFTS”.
2. Remove:

cylinder head nuts

cylinder head bolts

Loosen the nuts in the proper sequence as
shown.

Loosen each nut 1 / 2 of a turn at a time. After all
of the nuts are fully loosened, remove them.
EAS00227
CHECKING THE CYLINDER HEAD
1. Eliminate:

combustion chamber carbon deposits
(with a rounded scraper)
Do not use a sharp instrument to avoid damag-
ing or scratching:

spark plug bore threads

valve seats
2. Check:

cylinder head
Damage / scratches
Replace.
3. Measure:

cylinder head warpage
Out of specification
Resurface the cylin-
der head.
Maximum cylinder head warpage
0.10 mm (0.0039 in)
a. Place a straightedge
1 and a thickness
gauge
2 across the cylinder head.
b. Measure the warpage.
c. If the limit is exceeded, resurface the cylinder
head as follows.
d. Place a 400
600 grit wet sandpaper on the
surface plate and resurface the cylinder
head using a figure-eight sanding pattern.
To ensure an even surface, rotate the cylinder
head several times.
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5-27
VALVES AND VALVE SPRINGSENG
NOTE:
NOTE:
NOTE:
NOTE:
EAS00237
REMOVING THE VALVES
The following procedure applies to all of the
valves and related components.
Before removing the internal parts of the cylin-
der head (e.g., valves, valve springs, valve
seats), make sure the valves properly seal.
1. Remove:

valve lifter
1

valve pad 2
Make a note of the position of each valve lifter
and valve pad so that they can be reinstalled in
their original place.
2. Check:

valve sealing
Leakage at the valve seat
Check the valve
face, valve seat, and valve seat width.
Refer to “CHECKING THE VALVE SEATS”.
a. Pour a clean solvent
a into the intake and
exhaust ports.
b. Check that the valves properly seal.
There should be no leakage at the valve seat
1.
3. Remove:

valve cotters
1
Remove the valve cotters by compressing the
valve spring with the valve spring compressor
2 and the valve spring compressor attachment
3.
Valve spring compressor
90890-04019, YM-04019
Valve spring compressor
attachment
Intake valve
90890-04114, YM-4114
Exhaust valve
90890-04108, YM-4108
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5-30
VALVES AND VALVE SPRINGSENG
NOTE:
NOTE:
EAS00240
CHECKING THE VALVE SEATS
The following procedure applies to all of the
valves and valve seats.
1. Eliminate:

carbon deposits
(from the valve face and valve seat)
2. Check:

valve seat
Pitting / wear
Replace the cylinder head.
3. Measure:

valve seat width
a
Out of specification
Replace the cylinder
head.
Valve seat width
Intake: 0.9
1.1 mm
Intake: (0.0354
0.0433 in)
Exhaust: 0.9
1.1 mm
Exhaust: (0.0354
0.0433 in)
: 1.6 mm (0.06 in)
a. Apply Mechanic’s blueing dye (Dykem)
1
onto the valve face.
b. Install the valve into the cylinder head.
c. Press the valve through the valve guide and
onto the valve seat to make a clear impres-
sion.
d. Measure the valve seat width.
Where the valve seat and valve face contacted
one another, the blueing will have been re-
moved.
4. Lap:

valve face

valve seat
After replacing the cylinder head or replacing
the valve and valve guide, the valve seat and
valve face should be lapped.
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5-35
Order Job / Part Q’ty Remarks
1
2
3
4
5
6
7
8
9Removing the stator coil assembly
Rider seat
Fuel tank
Left side cowling
Bottom cowlings
Engine oil
Stator coil assembly lead coupler
Plug
Generator rotor cover
Gasket
Dowel pin
Generator rotor assembly
Dowel pin
Bearing housing
Collar1
1
1
1
2
1
2
1
1Remove the parts in the order listed.
Refer to “SEATS” in chapter 3.
Refer to “FUEL TANK” in chapter 3.
Refer to “COWLINGS” in chapter 3.
Drain.
Refer to “CHANGING THE ENGINE OIL”
in chapter 3.
Disconnect.
10 Nm (1.0 m
kg, 7.2 ft
lb)
12 Nm (1.2 m
kg, 8.7 ft
lb)
12 Nm (1.2 m
kg, 8.7 ft
lb)
12 Nm (1.2 m
kg, 8.7 ft
lb)
10 Nm (1.0 m
kg, 7.2 ft
lb)
10 Nm (1.0 m
kg, 7.2 ft
lb)
14 Nm (1.4 m
kg, 10 ft
lb)
22 Nm (2.2 m
kg, 16 ft
lb)
22 Nm (2.2 m
kg, 16 ft
lb)
STARTER CLUTCH AND GENERATORENG
STARTER CLUTCH AND GENERATOR
STATOR COIL ASSEMBLY
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